Research on the Aviation Application of New High Strength Copper Aluminum Alloy Composite Materials

Abstract The aerospace industry demands conductor materials that combine high conductivity with lightweight, high-strength, and corrosion-resistant properties to support efficient electrical systems. This study explores the potential of copper-clad aluminum composite conductors, which combine copper’s conductivity with aluminum’s lightweight advantages, as a promising solution for aerospace applications. The research systematically evaluates the physical, chemical, and mechanical properties of copper-aluminum composite conductors, comparing them to pure copper and aluminum alloys in terms of weight, conductivity, tensile strength, and corrosion resistance. The results demonstrate that copper-aluminum composites offer a significant weight reduction without compromising electrical performance, making them suitable for use in aircraft wiring systems. Furthermore, the study highlights the technical challenges involved in manufacturing these composite materials, including the complexities of production and the need for new testing methods for compatibility with existing aerospace connectors. The study concludes that copper-clad aluminum conductors hold substantial promise for reducing aircraft weight, enhancing efficiency, and contributing to the development of cost-effective, high-performance aerospace materials.