Solar power-driven airplane features several ultra-performance plastics

03-Apr-09

A portfolio of ultra-performance polymers from Solvay Advanced Polymers, LLC by the name of Spire® Ultra Polymers are making strong inroads in demanding aerospace applications such as hardware, fasteners, and mechanical components. These ultra-performance polymers have found acceptance in Solar Impulse, a two-ton solar-powered airplane that is being developed by a European industry consortium which includes several Solvay business units. The goal of the renewable energy project is for one pilot to fly day and night around-the-world making scheduled stopovers in an airplane that is completely powered by solar energy. The company's broad portfolio of ultra-performance polymers, which includes Torlon® polyamide-imide (PAI), KetaSpire® polyetheretherketone (PEEK), AvaSpire® modified PEEK, and PrimoSpire® self-reinforced polyphenylene (SRP), delivers weight reduction, freedom from corrosion, design flexibility, parts consolidation, and long-term reliability in metal replacement parts. The airplane's wingspan is equal to that of an Airbus A380 and the weight of its throttle system is reduced 35% by using Torlon® polyamide-imide (PAI) for its the friction control spacers and stator due to high strength and stiffness and broad thermal performance. Carbon fiber-reinforced KetaSpire PEEK is used for the friction control axis and PrimoSpire self-reinforced polyphenylene (SRP) for the screws, nuts, washers, and printed circuit board spacers. KetaSpire PEEK are said to retain mechanical properties up to 300 C and delivers a strong balance of chemical resistance, ease of processing, and excellent wear and fatigue resistance. The corrosion-resistant fasteners made of PrimoSpire SRP are expected to provide a 50% to 70% weight reduction versus aluminum and titanium. The material's strength-to-weight ratio is greater than aluminum or stainless steel and approaches that of titanium. PrimoSpire SRP is claimed to be the industry's stiffest and strongest unreinforced polymer, offering an exceptional combination of surface hardness, chemical resistance, and inherent flame resistance.