High-Flying Solutions: Advanced Materials Elevating Aerospace Safety and Performance
“Aviation is proof that given the will, we have the capacity to achieve the impossible.” — Eddie Rickenbacker
The idea of soaring into the skies has long been a captivating and exhilarating thought. Aerospace defies gravity, symbolising adventure, exploration, and endless possibilities. However, high altitudes require engineering that is innovative, precise, and can adhere to stringent safety regulations and requirements while pushing the boundaries of flight.
From the design of commercial aeroplanes to developing spacecraft for outer space exploration and discovery, aerospace engineers are always at the forefront of technological advancements.
High altitudes provide one of the most demanding requirements for aircraft materials due to continuous exposure to rapid temperature fluctuations and other challenging environmental conditions. In response to these challenges, advanced foam, tape and film materials work behind the scenes to help enhance the performance, durability and safety in both interior and exterior aircraft structures.
Fasten your seatbelts as we ascend into specially crafted materials to support bonding, protection and insulation needs critical for today’s aerospace industry.
In this discussion with Christopher Dickens, Global Market Manager, Mobility, we narrowed in on five key challenges and eight solutions in aerospace applications. We explored advanced materials, including silicone foams, thermal spray masking tapes, PTFE tapes, and composite moulding tapes as go-to solutions for take-off.
In this article
Challenge #1: Securing Aircraft Interiors
Aircraft interiors must meet strict safety requirements, such as fire resistance and low toxicity, while ensuring passenger comfort. Silicone materials, such as Norseal® Silicone Rubber, offer exceptional properties for various applications, including gasketing, thermal insulation, and soundproofing.
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Solution #1: Fire Resistance and Low Toxicity
Silicone foams and adhesives are highly valued for their flame resistance. In the event of a fire, these materials can withstand extreme heat without propagating flames, producing minimal smoke and releasing fewer harmful gases. This makes them ideal for use in cabin components, where passenger safety is paramount.
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Solution #2: Environmental Gasketing, Thermal Insulation, and Floor Cushioning
Silicones provide superior thermal insulation, maintaining their flexibility across temperatures from -100°C to over 250°C. This makes them perfect for high-altitude environments, where extreme temperature changes are common. Silicone solutions play a critical role in ensuring the structural integrity of the aircraft. They are often utilised to form gasket seals that provide a protective barrier to external elements, including ultraviolet rays and ozone gas, air, dust, and moisture including rain, sleet, snow and frost. They can also be used as thermal insulation due to their unprecedented ability to withstand wide temperature ranges. Additionally, silicone foams offer acoustic insulation, reducing cabin noise for a quieter and more comfortable passenger experience.
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Solution #3: Aircraft Flooring Tapes
Another small, often overlooked detail within an aircraft interior is its carpet. Aircraft carpets endure heavy foot traffic and the weight of trolleys. Biolink® relink 2318, relink 2521, and relink TC1513 flooring tapes are designed for securing carpets to composite floors. These tapes offer a strong bond while being removable and residue-free. Flame retardant and halogen-free options ensure safety and regulatory compliance, while maintaining comfortable and visually appealing cabin environments.
Challenge #2: Engine Gasketing
Successful operation of an aircraft is dependent on the efficiency and performance of its engine. Our newest product portfolio, Norgard®, includes performance-coated solutions and performance films that can help engines perform at their highest level for longer.
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Solution #4: Ensuring High-Level Engine Performance
In mission-critical turbine gasketing, products such as Zitex® Microporous PTFE Films can prevent fluid leakage across a boundary. These bondable, low-friction, abradable products help engines to perform at their highest level.
Challenge #3: Wire, Cable, and Harness Assembly
The intricate network of wires and cables in an aircraft is critical to its operation. PTFE, polyimide, and glass cloth tapes protect these components from abrasion, vibration, and environmental factors.
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Solution #5: PTFE and Polyimide Tapes for Wire Harness Protection
PTFE tapes are known for their heat resistance (up to 250°C) and low coefficient of friction, making them ideal for protecting wires from abrasion. They also provide chemical resistance against aviation fuels and oils. Kapton® polyimide tapes offer excellent electrical insulation and are lightweight, adding minimal mass while providing essential protection for wire harnesses.
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Solution #6: Glass Cloth Tapes
Glass cloth tapes, often treated with flame retardant coatings, are used in high-abrasion environments where wires face constant friction. These tapes are highly conformable and durable, making them suitable for aerospace applications that experience significant mechanical stress.
Challenge #4: Composite Moulding
The aerospace industry relies heavily on composite materials due to their strength-to-weight ratio. During the manufacturing process, composite parts are moulded using high-performance tapes to protect tooling and aid in part removal.
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Solution #7: Mould Release, Protection, Seaming, and Flash Masking Tapes
Tapes like PTFE glass laminate, PTFE glass cloth, and skived PTFE film are used as mould release liners to prevent composite parts from sticking to moulds. SGB6, a PTFE laminate tape, offers non-stick properties and a uniform surface finish, while CHR® 2255 Skived PTFE Tape provides dimensional stability, making it ideal for protecting and seaming mould surfaces.
Flash masking and hold-down tapes, such as CHR K201 & K202 (flash masking) and CHR M824 (PET tapes), ensure smooth bond lines during moulding and protect tools from resin leakage. These temperature-resistant tapes minimise rework and extend tool life, contributing to more efficient manufacturing processes.
Challenge #5: Thermal Spray Coating Protection
Critical components such as jet engines and turbine blades require thermal spray coatings to enhance wear resistance and performance. Tapes play a crucial role in masking areas that must remain uncoated, protecting them during the thermal spray process.
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Solution #8: Thermal Spray Masking Tapes
Thermal spray tapes such as CHR 2975 (silicone rubber coated glass cloth) and CHR H7575 (multilayer construction) are designed to endure the extreme conditions of processes such as HVOF (High Velocity Oxygen Fuel). These tapes provide excellent resistance to abrasion and burning, clean removal, and high-temperature capability. For flexibility in hard-to-reach areas, CHR 2925 Glass Foil Tape offers the adaptability and durability required for precise masking.
From interior comfort to the protection of critical engine and structural components, the advanced materials discussed here, ranging from silicone foams to thermal spray tapes, are essential in meeting the demands of modern aerospace engineering. These solutions not only improve performance but also ensure the safety and reliability of critical aerospace systems. In an industry where precision and durability are non-negotiable, these materials enable manufacturers to meet the strictest standards while continuing to push the boundaries of innovation.
As Eddie Rickenbacker so aptly put it, “Aviation is proof that given the will, we have the capacity to achieve the impossible.” The evolution of aerospace materials exemplifies this spirit. From high-strength composites to temperature-resistant tapes, these innovations remind us that with the right tools and technologies, we can overcome even the most complex challenges, reaching new heights in aviation and beyond.