Bottlenecks in The Development of New Aerospace Materials

Bottlenecks in the Development of New Aerospace Materials

Despite significant progress in 2025, the development of new aerospace materials still faces multiple critical bottlenecks, primarily concentrated in technology R&D, industrialization, and industrial chain collaboration.

I. High Difficulty in Fundamental Material Technology R&D

There is a disconnect between material design theory and experimental verification. The mechanisms linking the microstructure and properties of new materials, such as composites and amorphous materials, are not fully understood. This leads to material design relying on empirical trial and error rather than theoretical guidance. For example, the interfacial bonding strength and thermal stability of carbon fiber composites remain difficult to control precisely, affecting their performance in high-temperature components.

Key performance indicators are challenging to breakthrough. Technical metrics like the temperature resistance of superalloys, specific strength of lightweight materials, and the absorption bandwidth of stealth coatings have long been stagnant. Taking aero-engine blade materials as an example, the service temperature of single-crystal superalloys is nearing its theoretical limit, and the rate of improvement in the temperature resistance of new materials is slowing down.

II. Limitations in Industrialization and Large-Scale Application

Production processes are complex and costly. The carbon fiber production process is lengthy, and steps like pre-oxidation and carbonization are energy-intensive. This results in the cost of domestic carbon fiber being significantly higher than imported products, limiting its large-scale application in aerospace. The powder preparation cost for 3D printed metal materials accounts for a major portion of the total material cost, making industrial promotion difficult.

Standardization and testing systems are incomplete. Performance testing standards for new materials have not been unified. Companies often need to conduct repeated verifications, prolonging R&D cycles. For instance, the non-destructive testing pass rate for additively manufactured aluminum alloy components is relatively low, affecting part reliability.

III. Insufficient Industrial Chain Collaboration and Resource Integration

There are poor connections between upstream and downstream sectors. Inadequate demand alignment between material R&D institutions and equipment manufacturing enterprises leads to some materials having either performance redundancy or deficiency. For example, the actual service life of a certain type of UAV using lightweight magnesium alloy was reduced due to lagging supporting anti-corrosion coating technology.

Key equipment and raw materials rely on imports. Core materials such as high-performance carbon fiber precursor and single-crystal superalloy castings for aero-engines still depend on imports. Domestic enterprise production capacity only meets a fraction of demand. The self-sufficiency rate of high-end equipment is low.

IV. Prominent Technical Bottlenecks in Emerging Fields

Shortcomings in eVTOL power materials. The insufficient energy density and high-temperature resistance of batteries for electric vertical take-off and landing aircraft result in limited range. The technology for controlling electromagnetic losses in lightweight motor materials is not yet mature.

Insufficient functional stability of smart materials. The cycle deformation life of shape memory alloys falls short of practical requirements. The repair efficiency of self-healing materials decreases in low-temperature environments, limiting their applicability in extreme conditions.

V. Policy and Ecosystem Support Need Improvement

Fragmented and duplicated R&D investment. Domestic new material R&D projects are scattered. The industry-academia-research collaboration mechanism is unsound, leading to low resource utilization efficiency.

Environmental constraints and cost pressures. The treatment cost for wastewater generated during carbon fiber production accounts for a significant portion of the total cost. Increasingly stringent environmental policies further compress profit margins. The production carbon footprint of composite materials for hydrogen energy aircraft storage tanks is higher than that of traditional materials, posing challenges for sustainable development.

Breakthrough Directions and Suggestions

• Strengthen the integration of basic research and digital technology. Establish materials databases and utilize AI to accelerate material screening and performance prediction.

• Promote strengthening and supplementing the industrial chain. Build pilot platforms to bridge the laboratory to production line transformation channel.

• Improve standards and testing systems. Formulate performance grading standards for new aerospace materials and establish authoritative third-party testing platforms.

By systematically breaking through the above bottlenecks, key areas of new aerospace materials are expected to achieve greater autonomy, supporting the goals of reducing the weight of next-generation aircraft and lowering energy consumption.

In summary, the development of new aerospace materials is at a critical stage transitioning from technological breakthroughs to large-scale application. Bottlenecks in basic theory, production processes, industrial chain collaboration, and emerging fields still require systematic resolution. In this process, innovation in supporting materials is equally crucial. For instance, Yinsu Flame Retardance Company has developed a series of halogen-free flame retardants, such as WADP-10, and PPAP-31, targeting the fire safety needs of carbon fiber composites in high-temperature and high-load environments. These products significantly enhance the flame retardancy and thermal stability of carbon fiber while maintaining its lightweight advantages. They also meet environmental requirements, providing crucial support for achieving safe weight reduction in aerospace components. They are expected to play key roles in areas such as cabin interiors and battery compartment protection. In the future, with deeper integration and enhanced collaboration capabilities, new aerospace materials are expected to achieve comprehensive breakthroughs in performance, cost, and sustainability.