CFRP (Carbon Fiber Reinforced Polymer) vs. Aluminum is a common comparison in aerospace, automotive, and other high-performance engineering applications. Here’s a detailed breakdown:
 1. Material Properties
	
		
			| Property | CFRP (Carbon Fiber) | Aluminum (e.g., 6061, 7075) | 
	
	
		
			| Density | ~1.6 g/cm? | ~2.7 g/cm? | 
		
			| Tensile Strength | ~500–1500 MPa (directional) | ~290–570 MPa | 
		
			| Stiffness (Modulus) | ~70–150 GPa (anisotropic) | ~69–80 GPa (isotropic) | 
		
			| Fatigue Resistance | Very good | Moderate | 
		
			| Corrosion Resistance | Excellent (non-metallic) | Good (can oxidize, but manageable) | 
		
			| Thermal Conductivity | Low (~5–10 W/m·K) | High (~120–220 W/m·K) | 
		
			| Thermal Expansion | Very low (near zero) | Relatively high (~23 ?m/m·K for 6061) | 
	
 
 
? 2. Usage in Aerospace
	
		
			| Use Case | CFRP | Aluminum | 
	
	
		
			| Aircraft Bodies | Modern aircraft (e.g., Boeing 787, Airbus A350) | Older gen aircraft (e.g., Boeing 737, A320) | 
		
			| Wings/Fuselage | Superior strength-to-weight ratio | Easier to fabricate and repair | 
		
			| Satellites/Space | Widely used due to low weight and no corrosion | Used with surface treatments | 
	
 
 
? 3. Manufacturing  Cost
	
		
			| Factor | CFRP | Aluminum | 
	
	
		
			| Manufacturing | Complex layup, curing, autoclaves often needed | Simple casting, forging, machining | 
		
			| Repairability | Difficult, needs specialist tools and skills | Easy to weld, rivet, replace | 
		
			| Cost | Much more expensive (5–20× aluminum) | Relatively cheap and widely available | 
	
 
 
 4. Summary: When to Use What
	
		
			| Situation | Preferred Material | 
	
	
		
			| Max weight savings needed | CFRP | 
		
			| Simple, cost-effective solution | Aluminum | 
		
			| High-temperature environments | Aluminum (CFRP degrades) | 
		
			| Custom, performance-optimized | CFRP | 
		
			| Ease of fabrication/repair | Aluminum |