Development and Life Cycle Analyses of Carbon Fiber Reinforced Polymer Tubular Parts for Metal Replacement in Aerospace Applications

Reducing the weight of aircraft components is a key strategy to improve fuel efficiency and reduce greenhouse gas emissions. Innovative materials such as carbon fiber reinforced polymers (CFRPs) and manufacturing techniques represent a possible solution for improved sustainability in the aerospace sector. In this context, this paper presents the design and the evaluation of the environmental and economic impacts of a CFRP tubular structural component, employed for supporting passenger seats of commercial aircraft, realized with the innovative FW process. At first, a simulation of the winding process was conducted to define the component layers, and then a FEM analysis was performed to identify the optimal layering of the tubular structure to support the defined loads. Subsequently, environmental and economic impacts were evaluated by means of life cycle assessment and life cycle costing methodologies. The comparison between the CFRP tubular structure and traditional aluminum alternative was conducted to identify the most sustainable solution. The analysis showed that the CFRP tubular component resulted in lower environmental impacts than the traditional alternative (i.e., about 70% lower considering the whole life cycle) mainly due to the reduced weight. However, the cost evaluation identified the CFRP alternative as the most expensive solution, with production cost 40% higher than the aluminum alternative.