Structural Efficiency of a Fuselage Truss System: Mechanics of Materials Insights into Advanced Alloy Configurations

A comparative finite element analysis (FEA) of aerospace-grade materials for use in the fuselage construction of a light aircraft, based on the Cessna configuration, is presented in this study. The aim of the study was to assess the stress response, deformation, strength-to-weight ratio, and stiffness-to-weight ratio of four potential materials: aluminum alloy 2024-T3, aluminum alloy 7075-T6, titanium alloy Ti-6Al-4V, and aluminum-lithium alloy (Al–Li). In order to reproduce the weight distributions of the wings, engine, and landing gear, loads were applied to a truss-based fuselage shape created in ANSYS Mechanical. While strength-to-weight and stiffness-to-weight ratios were computed analytically from material property data, von Mises stress and deformation fields were taken from static structural simulations under linear elastic circumstances. According to the results, the aluminum-lithium alloy (Al–Li) performed best in stiffness-to-weight performance, whereas titanium alloy Ti-6Al-4V performed best in stress resistance, deformation control, and strength-to-weight efficiency. Aluminum–Lithium Alloy, Aluminum 7075-T6, and Aluminum 2024-T3 were the next most appropriate candidates for lightweight, high-performance fuselage design, according to a comparative ranking. These results emphasize the significance of striking a balance between strength, stiffness, and weight efficiency in aerospace applications and offer quantitative insight into the material selection for light aircraft fuselage structures.