The advanced materials building a greener future for aerospace wiring systems
Sustainable aerospace practices are not limited to emissions. While the UK’s Jet Zero plan remains a priority for the industry, other strategies like material innovations should not be glanced over. An aircraft’s electronic cable system may be hidden, but it plays a vital role, comprising of composites, alloys and enhanced insulators serving to maximise sustainability efforts. Here, Jeff Wood, sales director at aerospace cable specialist WireMasters, explores the advancements made in sustainable cabling materials for aerospace applications and what challenges have driven the pursuit for innovation.
Keeping up with sustainability efforts across the aviation industry is challenging. However, reducing environmental impact while maintaining high safety and performance standards is an industry imperative. Aircraft wiring is no exception to this, and manufactures have started to implement innovative weight saving materials like aluminium alloy conductors, carbon fibre composites or polytetrafluoroethylene (PTFE) jacketing in airborne cable systems.
Weight reduction is a critical factor in improving fuel efficiency and reducing emissions. For one kilogram (kg) of weight saved, an aircraft saves approximately 0.03kg of fuel per 1,000 kilometres (km) which translated to a saving of around 0.0945 kg of carbon dioxide (CO₂) emissions per 1,000 km. Considering this, even the smallest weight change in wiring systems can make a difference.
Distributors play a key role in managing these challenges by collaborating closely with aerospace manufacturers. Broad inventories of advanced, compliant materials and technical support enables aerospace manufacturers to reap the sustainable benefits of a lighter cable system without compromising on safety and performance.
Breakthroughs in advanced material
Traditionally, aerospace cabling has relied on copper thanks to its excellent conductivity. However, its density contributes heavily to an aircraft’s weight, prompting the industry to explore alternative materials without compromising on performance.
Aluminium (AI) alloy conductors have infiltrated the market as a popular alternative to copper. Usually comprised of aluminium, copper, iron and magnesium, each metal’s individual properties contribute to the conductor’s resistance, creep resistance and strength.
While AI alloys don’t quite match up to copper’s conductivity amounting to 61 per cent of copper’s conductivity level, they offer up to 50 per cent weight reduction in wiring applications with the equivalent electrical resistance. This balance of conductivity and weight makes it suitable for avionic systems, improving fuel efficiency which aligns with the industry’s sustainability goals.
Longevity also plays a role in aerospace’s greener future. Longer lifespans of equipment don’t only save businesses money on maintenance costs; they also reduce the need to fully replace old systems. This minimises electronic waste and diminishes the need for frequent raw material extraction, which amounts to high carbon emissions.
Similarly, composite polytetrafluoroethylene (PTFE) jackets in aerospace wiring enable increased durability and resistance, crucial to longer operational lifespans while reducing footprint and weight.
PTFE jackets offer superior abrasion resistance, chemical resistance and operational performance in temperatures up to 260°C. This increased durability leaves cables with a service lifespan up to 30 years, minimising regular replacement and waste. These jackets also meet the stringent aerospace industry standard AS22759, which ensures insulator performance and quality.
Fibre optic cables are another advancement focusing on both performance and quality. Constructed from glass fibres, they are lighter than metal core cables typically weighing approximately 4 pounds per 1,000 feet while copper cable weighs around 39 pounds per 1,000 feet. It also offers higher bandwidth supporting transfer speeds up to 10 Gigabit per second (GBPS) and immunity to electromagnetic interference (EMI).
In aerospace applications, fibre’s improved signal integrity reduces the need for excess heavy shielding and simplifies cable design. This enables a substantial reduction in an aircraft’s weight, which enhances fuel efficiency without a compromise on performance reliability.
Supplying sustainability
Adopting sustainable, high-performance cabling that also meets industry standards is a process accelerated by supply chain partners like WireMasters.
Supply chain partners provide access to advanced materials in high demand like composites based on AS22759 standards and high temperature, halogen-free insulation materials. They also provide technical expertise aligned with the most up to date standards and regulations like the Restriction of Hazardous Substances (RoHS) or FAR 25 Appendix F to ensure such materials are used appropriately.
Working closely with OEMs, distributors ensure a seamless transition to a sustainable future for aviation driven by advanced materials. Supply chain coordination like forecasting, inventory planning and demand visibility tools facilitate this transition, which amounts to lighter, more efficient and durable aircraft wiring systems. Consequently, we’re left with more sustainable aircraft cable systems with extended maintenance cycles that contribute towards reduced emission goals like Jet Zero.
To learn more about WireMasters’ custom service for aerospace equipment, visit www.wiremasters.com/services
