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Conceptual Design and Aerodynamic Configuration of the Relithia Nova: A 2000kg Hybrid-Electric STOL Aircraft2026-01-0660To be published on 07/01/2026
This paper presents the conceptual design of the Relithia Nova, a hybrid-electric Short Take-Off and Landing (STOL) aircraft engineered to provide essential connectivity to remote regions with limited aviation infrastructure, such as the South Pacific and Caribbean. Designed with a Maximum Take-Off Mass (MTOM) of 2,000 kg, the aircraft accommodates six occupants, including the pilot, and is optimized for operations on short, unprepared airstrips up to 2,000 ft elevation. The Relithia Nova employs a series-hybrid propulsion architecture featuring two wing-mounted turboshaft engines coupled with electric generators that drive propulsive rotors via a high-capacity lithium-ion energy storage system. This configuration ensures sustained power for high-lift generation while reducing emissions. Aerodynamically, the aircraft utilizes a high-aspect-ratio wing (AR=8.67) based on the NACA 23012 airfoil, chosen for its favorable lift-to-drag characteristics in subsonic flow (Mach 0.23 cruise
Chikwanha, Hendrick Tafadzwa
Design-Driven Sustainability of Automotive Components: A Comparative LCA from Conventional to Metal and Composite Additive Manufacturing2026-37-0037To be published on 06/09/2026
The increasing pressure to decarbonize manufacturing systems is pushing industry beyond conventional lightweighting strategies toward material and process paradigms, capable of delivering functional performance with radically lower environmental impact. In this context, polymer-based composite Additive Manufacturing (AM) offers an underexplored yet highly promising pathway for sustainable production of load-bearing components. This study presents a preliminary comparative cradle-to-gate Life Cycle Assessment (LCA) of a Formula SAE brake pedal, assessing the environmental transition from conventional CNC machining of Aluminum 7075-T6 to additive manufacturing solutions, with specific focus on Carbon-Fiber-Reinforced Polymer (CFRP) composites. Two topology-optimized designs, respectively for Powder Bed Fusion (PBF) in AlSi10Mg and Material Extrusion (MEX) in PETG-CF are compared to machined aluminum benchmark. The analysis is integrated in the product and process design following ISO
Dalpadulo, Enrico, Russo, Mario, Apté MD, Raphaëlle, Leali, Francesco
A predictive methodology for 3D-CFD simulation of piston thermal field in sustainable high-performance engines2026-37-0002To be published on 06/09/2026
In recent years, especially in high performance engines, the thermal stress of pistons has gradually increased due to the implementation of various technologies, aimed at meeting emission reduction and specific power increase requirements. If the heat is not properly dissipated, cracking and plastic deformation of the material as well as formation of hot spots triggering self-ignition can occur. To overcome these problems, one or more jets of oil are directed towards the piston undercrown region, impacting at high speed. This technique ensures immediate cooling and allows the engine performance to be increased without compromising the useful life. In order to optimize the oil jet effectiveness, 3D-CFD can be proficiently adopted. In this regard, the aim of this work is to define a robust numerical methodology able to simulate oil jet impingement and piston thermal field. In particular, a 3D-CFD Volume-of-Fluid (VoF) simulation is used to numerically assess the oil jet impact and
Duni, Andrea, Berni, Fabio, Breda, Sebastiano, Fontanesi, Stefano, Gilioli, Filippo
Improvement of rCF behaviour through the introduction of NF2026-37-0039To be published on 06/09/2026
The use of recycled carbon fibres (rCF) allows for reduction of emissions impacting energy and resource requirements. A major drawback of using rCF composites is the discontinuous nature of the fibres as this limits the performance and applications. The present investigation aimed to overcome some of these limitations by manufacturing hybrid composites by combining rCF and natural fibres (NF). One of the key observations was a significant change in the failure mode of hybrid samples under various loading scenarios, where the composite did not shatter but rather failed in a controlled manner. Initial results also showed an overall improvement impact properties in comparison to plain rCF. Similar performance was observed in other tests. Research was focused on determining the most effective ply sequencing under different types of loading and understanding the effect of the ply sequence on the failure mechanisms. It was determined that depending on the application, the layups does effect
Hnatyk, Dawid, Chrysanthou, Andreas, De Vuyst, Tom, Ismail, Sikiru
Predictive model and analysis of the resultant force in the dry machining of Mg-4Zn/Si3N4 nanocomposites2026-26-0762To be published on 06/01/2026
In aerospace and automotive applications, the usage of magnesium (Mg)-based alloys and composites reduces the structural weight due to their low density. They also possess good specific strength and are abundantly available. The Mg-4Zn alloy is one such Mg-based alloy that is also biodegradable and biocompatible. In spite of these advantages, there is a strong need and scope to improve its wear resistance and mechanical properties. Mg-4Zn nanocomposites with Si3N4 reinforcements (also a biocompatible bio-ceramic) are hypothesized to possess superior properties. Sustainable machining with minimal subsurface defects and minimal energy consumption is necessary to manufacture components from these vacuum stir-cast nanocomposites. The resultant machining force (Fr) is a good indicator of subsurface quality and energy consumption in machining. The addition of Si3N4 reinforcement to improve the properties of the Mg-4Zn alloy could introduce challenges in machining and could influence Fr. To
N, Anand, Shaju, Tony M, G, Nagamalleswara Rao, D, Bijulal, K, Jayaprakash Reddy, K, Vijayan, Chaman, Joji J
Conceptual design of CFRP sandwich structures interfacing cryogenic tankages in rockets2026-26-0761To be published on 06/01/2026
Interstage and intertank structures of rocket's cryogenic stages face a critical design challenge due to the large thermal contractions in metallic cryogenic tanks after propellant filling. Existing design concepts such as metallic skirts, truss designs, corrugated shells, and special brackets are not mass-efficient. Their direct attachment to cryogenic tanks, combined with the inherently high thermal conductivity of metals, also causes significant heat leakage and necessitates additional thermal insulation. Overall, these configurations result in high mass penalties and reduced efficiency. To overcome these limitations, the present study proposes a Carbon Fiber Reinforced Plastic (CFRP) sandwich composite structure featuring specially designed slits near the tank interfaces. These slits enable controlled deformation and effective stress relief. Furthermore, to minimize the transfer of cryogenic temperatures into adjoining structural regions, thermally insulating Glass Fiber Reinforced
Bhalerao, Sandesh Popat, Gupta, Yogesh Kumar, Madhukumar, P.
Evaluation of Thermal and Thermo-Mechanical Behavior of Ramie Fiber/Delrin Composites for Aircraft Cabin Components2026-26-0754To be published on 06/01/2026
Abstract This study investigates the fabrication and evaluation of Delrin (polyoxymethylene, POM) composites reinforcing 5, 10, 15, and 20 wt.% chopped ramie fiber (RF). The polymer composites were fabricated via injection moulding technique. Glass transition temperature (Tg), thermal conductivity, Vicat softening temperature (VST), heat deflection temperature (HDT), melt flow index (MFI), and coefficient of linear thermal expansion (CLTE) were the various thermo-mechanical and thermal characteristics of the composites that were systematically evaluated as per the ASTM standards. The Delrin matrix's performance was drastically altered by the addition of RF. Within the formulations, the composite with 15 wt.% RF had the best combination of properties: higher VST and HDT values responsible for more dimensional stability at high temperatures, lower CLTE producing lesser thermal expansion, comparatively better thermal conductivity and more heat dissipation. Eventually, there was a moderate
S, Thirumalvalavan, Senthilkumar, N., Selvarasu, S
Evaluating Volume and Hardness change in Fluorocarbon and Ethylene Propylene Rubber Elastomers: Effects of Fluid Aging2026-26-0758To be published on 06/01/2026
Abstract: This research paper investigates the performance of FKM (Fluorocarbon) seal material when exposed to a 50:50 ethylene glycol-water mixture. The study aims to determine the volume change percentage and Hardness change of FKM elastomers under standardized testing conditions. The experimental approach follows ASTM D471 and ASTM 2240 guidelines, focusing on weight and hardness measurements of the test samples to establish a success criterion. The results provide critical insights into the chemical compatibility and durability of FKM elastomers in Aerospace and industrial applications where ethylene glycol-water mixtures are commonly used. The findings contribute to enhanced material selection and design considerations for sealing applications subjected to glycol-based fluids. Samples of FKM material were immersed in the fluid at controlled temperatures and durations, simulating real-world operational conditions. The primary metric of interest, volume change percentage and
Yarolkar, Makrand, Patil, Sandip, Singh, Tanul
Finite Element Approach for Fatigue Life Prediction of Threaded Bolts with Experimental Validation2026-26-0745To be published on 06/01/2026
Predicting the fatigue life of threaded bolts is crucial in aerospace and mechanical assemblies where cyclic loading can cause early joint failure. Previous research conducted experiments to develop S-N curves for high-strength bolts under different pretension and temperature conditions (Zhang et al. 2024). However, there are a very few numerical methods that can replicate these results, especially for bolts with screw threads. In this work a finite element analysis (FEA) methodology is developed to predict the fatigue performance of threaded bolts under axial loading and validated using the experimentally derived Series-1 S-N data for M20 high-strength bolts. The approach includes detailed FEA modelling (3D solid) with explicit thread geometry to capture local stress distributions under cyclic tensile loading. Peak stress amplitudes are employed to estimate fatigue life by applying the Basquin relation and the Series-1 S-N curve. The results are compared with the calculated fatigue
K R, Lesanth, S, Suhail Ahmed, C, Arunvetrivel, P, Krishnakumar, P S, Premkumar, Vasantharaj, C
Augmented Reality and Multimodal Interfaces for Astronaut Training and In-Orbit Operations2026-26-0796To be published on 06/01/2026
Augmented Reality (AR) and multimodal human–machine interfaces (HMI)—combining visual overlays, voice, gesture, eye-tracking, and biometric sensing—are now maturing into flight-relevant technologies capable of transforming astronaut training and in-orbit operations. These interfaces reduce task time, lower error rates, and mitigate cognitive load, thereby strengthening both crew autonomy and mission safety. For India, the timing is critical: Gaganyaan human spaceflight program is approaching decisive crewed missions in the late 2020s, and the Bharatiya Antariksh Station (BAS) is targeted for the 2030s. AR/MMI can be positioned not as an accessory but as a core enabling system for training throughput, real-time crew support, and resilient station operations. This paper provides (i) an overview of India’s current scenario, including Gaganyaan astronaut training ecosystems, IIT Madras collaborations on AR/VR, and Vyommitra humanoid readiness; (ii) synthesis of global case studies—NASA
Yadav, Anoop Singh
Electrical Harnessing in Satellite Launch Vehicles of ISRO – Methods for Sustainable, Safe, and Reliable systems2026-26-0779To be published on 06/01/2026
The electrical harness serves as the "neural network" for satellite launch vehicles, providing the interfaces for all guidance, health monitoring, and control systems during a mission. This system is composed of cables, and connectors. The wires are made of metallic conductors, typically copper plated with silver or gold to enhance conductivity and prevent oxidation. These conductors are insulated with polymeric materials such as PTFE, Kapton, ETFE, or TKT. Connectors, which are the interface points for electrical circuits, consist of gold or nickel-plated copper contacts housed within a shell. A typical launch vehicle contains an extensive network of electrical harnesses, with approximately 4,200 connectors and 110,000 meters of cable, which contributes to about 30% of the vehicle's total weight. The weight is mostly due to the polymeric insulation rather than the conductors. Challenges and Solutions for Sustainable Systems The paper highlights several key issues with current
K S, Nithish, TR, Binny, D S, Praveen Kumar
IMPROVEMENT OF MECHANICAL PROPERTIES OF SYNTHETIC FIBER REINFORCED COMPOSITES THROUGH ADDITION OF GRAPHENE OXIDE2026-26-0753To be published on 06/01/2026
Unmanned Aerial Vehicles (UAVs) demand structural materials that are lightweight, strong, impact-resistant, and durable in diverse environments.The synthetic fiber and natural fiber reinforced polymer composites have varying mechanical performance depending on the fibermatrix interfacial properties. This research analyzes the influence of Graphene Oxide (GO) nano fillers on mechanical properties of composites. Firstly, the epoxy resin was was modified by incorporating different weight percentage of graphene oxide. This resin was used to make an composite laminate using different materials (Carbon, Glass and Natural Fibers). Then the composites were put through the tensile, compression, flexural, and impact strength tests. The synthetic fiber and natural fiber reinforced polymer composites have a significant improvement in mechanical properties due to the addition of graphene oxide.
Manoharan, Dinesh, Langford, Peter, M.K., Padmanabhan, R, Prithviraj, Rajkumar, Subbiah, Karthikeyan, Ravikumar, Veeramuthu, Balasubramaniyan, Gunaseelan, John, T, Thangaraj
Advancing Aerospace Interiors: Evaluation of the In-House Polymer Pellet Additive Manufacturing System2026-26-0765To be published on 06/01/2026
The Elektra printer is an open-source, pellet-based (FGF) 3 axis additive manufacturing system developed by Collins in collaboration with Pollen AM to enable large-scale, cost-efficient 3D printing using standard polymer pellets. In alignment with the Make in India program, Elektra represents a significant step toward localized, industrial-scale additive manufacturing that delivers affordability, flexibility, and performance for aerospace and allied industries. The system provides four major advantages. First, it enables cost-effective part production by leveraging standard injection molding grade thermoplastic pellets instead of expensive proprietary feedstocks. Second, its large build volume (800mm*800mm*400mm) supports the manufacture of tools, fixtures, and structural parts often restricted by conventional systems. Third, Elektra is compatible with a broad range of engineering and high-performance polymers that are flame retardant, ensuring adaptability for multiple use cases
Kini, Aditya Deepak, Sundar, Santosh
Wear Resilience Characteristics of 2% Silicon Nitride Strengthened AZ31 Magnesium Composite2026-26-0740To be published on 06/01/2026
To develop magnesium matrix composites, ceramic silicon nitride (Si3N4) particles are used to strengthen the magnesium (AZ31) matrix by adding 2 wt.%. The composite is developed by disintegrated melt deposition vacuum stir casting method. Microstructural studies reveal the presence of Si3N4 particles and their uniform distribution. A L9 orthogonal array planned using Taguchi’s experimental design is chosen for three wear parameters axial load (AL), rotational speed (RS), and time duration (TD) for trials as per G99 standard in pin-on-disc apparatus. Experimental outcomes show a rise in axial stress; wear loss increases dramatically. Because the area of contact shrinks as sliding speed increases, wear loss diminishes dramatically. When the AL is low, CoF increases, and when the AL is large, CoF drops. When the sliding speed is increased, CoF decreases. To optimize multiple responses effectively, the TOPSIS method (Technique for Order of Preference by Similarity to Ideal Solution) was
Senthilkumar, N., Dhinakar Raj, C K
Retrofit Vibration Mitigation of Launch Vehicle Structures Using Thin Viscoelastic Coatings: Acoustic and Modal Study2026-26-0736To be published on 06/01/2026
Acoustic-induced vibrations pose a significant risk to launch vehicle hardware and payload reliability during critical phases such as lift-off and transonic phase. Reducing such vibrations is especially challenging when the hardware has already been fabricated, limiting the possibility of structural redesign. This study demonstrates a practical post-fabrication solution using a thin PC10 viscoelastic polymer coating applied externally to fully assembled hardware. The PC-10 Thermal Protection System (TPS) is a silicone polymer-based filled compound originally developed by VSSC, ISRO for ablative thermal insulation. Its viscoelastic properties make it suitable for energy dissipation under dynamic loads. Comprehensive evaluations were conducted using both acoustic testing at National Aerospace Laboratories (NAL), Bangalore, and Experimental Modal Analysis (EMA) at ISRO before and after coating application. Results show a substantial decrease in structure response from 150Hz to 2000Hz
Avirah, Nohin K, Panda, Ajay Kumar, Shaikh, Altafhusen
Investigating the Electrochemical Corrosion Behaviour of Bamboo Fiber-Marine Waste Reinforced Polymer Matrix Hybrid Composites for Light Weight Applications2026-26-0733To be published on 06/01/2026
This study investigates the corrosion behaviour of bamboo-crab shell fortified polymer matrix hybrid composites. Three unique hybrid composites were created utilizing the hand layup approach, with epoxy as the matrix material, 15 wt.% bamboo fibers, and varying quantities (3, 6, and 9 wt. %) of crab shell. Electrochemical corrosion tests were utilized to evaluate the hybrid composite's corrosion behaviour. The testing results reveal that epoxy-15 wt.% bamboo-6 wt.% crab shell (P2) composite has better corrosion resistance than epoxy-15 wt.% bamboo-3 wt.% crab shell (P1) and epoxy-15 wt.% bamboo-9 wt.% crab shell (P3). A potentiodynamic polarization test revealed an icorr value roughly five times lower than P1 and three times lower than P3 composites. Furthermore, the Nyquist plot obtained from the EIS study revealed that the P2 composite has a larger capacity loop than the P1 and P3 composites. It also indicates that the P2 composite is more resistant to corrosion than the other two
Senthilkumar, N., Srinivasan, D, G, Perumal, Balakrishnan, Deepanraj
Digitalization of Mechanical Labs for Enhanced Traceability and Virtual Verification2026-26-0715To be published on 06/01/2026
Digitalization is the process of leveraging digital technologies to transform business operations, processes, and models, enabling organizations to improve efficiency, create new value, and enhance customer experiences. It is essential as it enables data-driven decisions and reduces product development time. It’s easier to Digitalize new products however, transforming existing products and processes is a challenging task, as constituents are in various phases of lifecycle. Also, the existing/ legacy data acts as a starting point for future programs. Currently, teams are spending hours to weeks finding the right processes and data, costing $~14,000 per test based on labor hours. To tackle this challenge, Mechanical labs are digitalizing their data and processes alongside physical tests via 3DEXPERIENCE application to capture data in digital models and ensure traceability for which Requirement Functional Logical Physical (RFLP) framework is leveraged. This traces Requirements to its
Karpur, Anoop, Inapakolla, Bharat Kumar, Harris, Jason
Assessment of Injection Gate Location effects on Mechanical Performance of Short Fiber Reinforced Plastic Components using Digimat2026-26-0746To be published on 06/01/2026
The mechanical performance of short fiber-reinforced plastic (SFRP) components is highly sensitive to fiber orientation, which is significantly influenced by the injection gate location during the molding process. Traditionally, gate placement decisions are driven by warpage minimization strategies, often overlooking mechanical performance under diverse load cases. This research introduces an automated workflow within Digimat-MS that integrates injection gate optimization into the early design phase, leveraging Integrated Computational Materials Engineering (ICME) principles. The proposed methodology enables engineers to upload either of Marc, Abaqus or Ansys input decks, select a component of interest, assign material cards, and define gate scenarios. A Design of Experiments (DOE) is then executed locally or remotely, allowing Digimat to simulate and evaluate multiple gate configurations. The system aggregates results and identifies optimal gate locations based on the initiation of
Kauthale, Tanmay, Madhavan, Vinay, Soni, Ganesh
Reducing Test Campaigns through Advanced Yield Surface Modeling for New Aircraft Metal Grades2026-26-0755To be published on 06/01/2026
Qualification of new aerospace alloys requires extensive mechanical testing to capture anisotropy and ensure reliable performance under complex loading conditions. This process is costly and time-consuming, particularly with emerging manufacturing routes such as additive manufacturing. Advanced yield surface prediction offers a route to reduce test campaigns by linking microstructural features to macroscopic constitutive models. In this work, Digimat is employed as a multi-scale material modeling platform to generate yield surfaces of polycrystalline metals using computational homogenization. Representative volume elements (RVEs) are constructed from experimental texture and grain morphology data, and their response under multiaxial loading is simulated using a crystal plasticity framework. The computed yield loci are then fitted with phenomenological functions (e.g. Barlat2000), enabling calibration of anisotropic yield models from virtual testing. As a case study, an AA6016-T4 sheet
Padhan, Manas, Uppaluri, Rohith, Lemoine, Guerric, Soni, Ganesh
Development of Graphene filled Polypropylene Nanocomposite for Aerospace Application2026-26-0739To be published on 06/01/2026
Polypropylene, a commodity plastic, is the semi-crystalline thermoplastic widely used in high volume for general purpose applications. Polypropylene is the macro molecules of soft and weak backbone, which by reinforcement of fillers in different forms such as fiber, spheroids, nanotubes, flakes, etc., can influence its mechanical, thermal, electrical, creep resistance, and flame resistance properties for use in aerospace applications. Currently, polycarbonate and nylon plastics are used in aerospace applications, however, they are expensive compared with polypropylene. In this thesis, efforts are put to study the effect of reinforcement fillers in the properties of polypropylene composite, primarily the mechanical and flammability properties. The matrix element, polypropylene co polymer and reprocessed polypropylene blended in equal ratio, are coupled with the dispersing phases such as graphene, mica, fumed silica, and polydimethylsiloxane polymer. Effect of graphene as reinforcing
Govindaraju, Parthasarathy
Non-Intrusive Fatigue Detection and Alerting for Pilots2026-26-0793To be published on 06/01/2026
Pilot fatigue represents a critical concern in aviation safety, as it can significantly impair cognitive functions, decision-making abilities, and reaction times. In addition to decreasing performance, chronic fatigue has negative long-term health effects. Possible causes of fatigue include sleep loss, extended time awake, circadian phase irregularities and workload. Conventionally, the risk due to fatigue in aerospace is reduced by limiting pilot's flying hours and controlled rest requirements. Despite regulations on flying hours and optimal rostering, fatigue cannot be prevented completely. Hence, there is need to detect pilot fatigue in real time, annunciate in cockpit and transmit the information to airliners post-flight for appropriate fatigue risk management. There is ongoing research to detect pilot fatigue using devices that can capture Electroencephalogram (EEG) and Electrocardiogram (ECG). Though these devices have high fidelity, they are intrusive and can limit pilot
Nyamagoudar, Vinayak, P R, Namratha, Ramachandran, Venkataramani
Porosity Matters: Multiscale Simulation of Composite Panel Performance in Aerospace Structures2026-26-0731To be published on 06/01/2026
Porosity in carbon fibre reinforced polymers (CFRP) remains a critical concern for aerospace engineers, as even minor voids introduced during manufacturing can undermine the reliability of structural components. This work explores the influence of interply porosity on composite panel behaviour, employing a multiscale simulation approach that bridges material characterisation and full-scale structural analysis. The study begins with virtual coupon testing using Digimat-VA and Digimat-MF, enabling the prediction of material allowables and the assessment of defect variability. Homogenised material properties derived from these simulations are then applied to detailed panel models constructed in MSC Apex, ensuring accurate representation of layup and orthotropic behaviour. The workflow can support a range of structural load cases, allowing for the evaluation of stiffness, buckling, or other relevant scenarios as dictated by aerospace certification requirements. Nonlinear finite element
Savane, Vishal, Kumar, Rajat
Investigation of Aluminium Alloy Composites Reinforced with Zirconium oxide and Solid Lubricant Attributes for Brake and Clutch Components of Aircrafts2026-26-0752To be published on 06/01/2026
For brake and clutch components of aircraft, which require higher mechanical strength and wear resistance, lightweight aluminum composites were developed by infusing solid lubricant. In this study, hybrid composites were developed using the powder metallurgy route, using aluminum alloy AA356 and various amounts of zirconium oxide (ZrO₂) (0, 5, 10, 15, and 20 wt.%) as reinforcements. A solid lubricant, hexagonal boron nitride (hBN), at a fixed 5 wt.% is considered. Following the appropriate ASTM guidelines, the specimens were mechanically characterized by measuring their density, porosity, micro-hardness, compression strength, impact strength, and flexural strength, among other properties. The findings showed that the composites' physical and mechanical behaviour were greatly affected by the addition of ZrO₂.Porosity increased as a result of particle clustering and interfacial voids, while density increased gradually as ceramic content increased. Consistently increasing ZrO₂ addition
Senthilkumar, N.
Drilling Studies on Sustainable Lightweight Hybrid Polymer Matrix High Performance Nanocomposites2026-26-0732To be published on 06/01/2026
Worldwide, engineers are exploring the possibility of using polymer composites in their quest for lightweight materials. In an effort to create polymer composites that are less harmful to the environment, the use of biodegradable polymers has been investigated in recent years. Injection molding was used to create a biodegradable polymer composite containing 20 wt.% vetiver fibers (VFs) and 2 wt.% nano-silica (nSiO2) obtained from pearl millet. Parts for unmanned aerial vehicles, interior cabin panels, seating structures, and secondary structural components were made of this composite. Desirability analysis was used to examine and optimize machining (drilling) studies that were designed according to Taguchi's design (L9 orthogonal array). Surface roughness (Ra) and delamination factor (DF) were taken as outputs, while spindle speed (SS) ranging from 1000 to 3000 rpm, feed rate (FR) from 15 to 45 mm/min, and drill diameter (DD) from 6 to 10 mm were used as inputs. The developed
Senthilkumar, N.
Hybrid Digital Twin for Aero-Engine Bearing Prognostics: A Physics-Informed Machine Learning Approach to RUL Prediction2026-26-0718To be published on 06/01/2026
Unscheduled maintenance due to the failure of critical components, such as aero-engine rolling element bearings, is a leading cause of costly Aircraft-on-Ground (AOG) events; consequently, current time-based maintenance practices are inefficient and prone to risk. This paper develops a resource-efficient Hybrid Digital Twin (HDT) model for an engine bearing, focusing on the dynamic prediction of spall growth due to Rolling Contact Fatigue (RCF), thereby enabling a condition-based maintenance paradigm. The HDT architecture integrates two core models: (1) a physics-informed model that uses established life and fatigue theory to define initial degradation thresholds and constrain the failure envelope, and (2) a data-driven Recurrent Neural Network (RNN) (specifically, an LSTM) for dynamic degradation rate modeling. The methodology utilizes a Monte Carlo simulation coupled with RCF progression equations to generate a large, synthetic run-to-failure dataset under varying operational loads
Mohamed, Abbas
Lightweight Magnesium Nanocomposites with Enhanced Wear Resistance for Landing Gear Application2026-26-0751To be published on 06/01/2026
This study systematically evaluated the wear behaviour of an AZ61 magnesium alloy reinforced with 15 wt.% SiC and different amounts of multi-walled carbon nanotubes (MWCNTs) under dry sliding circumstances, adopting a pin-on-disc apparatus (ASTM G99). To identify the influence of factors like sliding speed (SS) (1-3 m/s), axial load (AL) (10-30 N), and MWCNT concentration (0-3 wt.%) on tribological performance, experiments were developed using a Central Composite Design (CCD) under Response Surface Methodology (RSM). Findings showed that wear loss (WL) was greatly amplified by increasing AL owing to localized heating and contact stresses, and that a compacted tribolayer was formed by increasing SS, which decreased WL but marginally raised the coefficient of friction (CoF). At moderate AL (15-20 N), SS (2 m/s), and 2 wt.% MWCNT, the wear resistance was significantly improved by improving load transfer and creating a lubricating carbon-rich coating, resulting in a decreased WL of around
Senthilkumar, N.
Thermal Management System in Commercial Aircraft: A Case Study on Passenger Egress System2026-26-0760To be published on 06/01/2026
It is known fact that Thermal management systems are essential to the safety, operational efficiency, and structural integrity of present-day commercial aircraft. Very critical insulation and thermal protection materials are utilized across various aircraft zones to mitigate extreme temperature challenges, ranging from cryogenic conditions at high altitude to pyrotechnic conditions at low altitude/ sea level. Some of the examples where specific materials at their functional role are, • In engine pylons and nacelles, high temperature alloys such as Titanium and Inconel, along with ceramic Matrix composites (CMCs) serve as firewalls and heat shields, which are designed to contain fires and protect primary structures. • In bleed air ducting, fiberglass or silica insulations blankets are employed to prevent thermal degradation of surrounding aluminum and composite components, when air at temperatures above 200 degree C flows. This paper focuses on the critical insulation and thermal
Govindaraju, Parthasarathy, Nanjundegowda, Harshavardhana
Aluminum Alloy, Hand Forgings, 6.2Zn - 2.3Cu - 2.2Mg - 0.12Zr (7050-T7452), Solution Heat Treated, Compression Stress-Relieved, and OveragedAMS4108G (Current)4/21/2026
This specification covers an aluminum alloy in the form of hand forgings 8 inches (203 mm) and under in nominal thickness and of forging stock (see 8.6).
AMS D Nonferrous Alloys Committee
Copper-Beryllium Alloy, Bars, Rods, Shapes, and Forgings, 98Cu - 1.9Be, Solution Heat Treated (TB00)AMS4650P (Current)4/21/2026
This specification covers a copper-beryllium alloy in the form of bars, rods, shapes, and forgings (see 8.5).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Extruded Profiles (2065-T84), 4.2Cu - 1.2Li - 0.52Mg - 0.32Mn - 0.32Ag - 0.1Zr, Solution Heat Treated, Stress Relieved by Stretching and Artificially AgedAMS4366B (Current)4/21/2026
This specification covers an aluminum-lithium alloy in the form of extruded profiles with a maximum cross-sectional area of 19 square inches (123 cm2) and a maximum circle size of 11 inches (279 mm) from 0.040 to 0.499 inch (1.00 to 12.50 mm) in thickness (see 8.6).
AMS D Nonferrous Alloys Committee
Steel Bars, Forgings, Mechanical Tubing and Forging Stock, 1.2Cr - 3.25Ni - 0.12Mo (0.07 - 0.13C) (9310), Premium Aircraft-Quality, Electroslag Remelted or Consumable Electrode Vacuum RemeltedAMS6267L (Current)4/21/2026
This specification covers a premium aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock.
AMS E Carbon and Low Alloy Steels Committee
Investigation of Metallurgical and Mechanical Behaviors of AA6061-AA2017 Joints Produced by Single- and Double-Pass Friction Stir Welding: Influence of Base Material Position and Post-Weld Shot Peening Technique05-19-04-00264/13/2026
The growing demand for lightweight, high-strength materials in marine and aerospace structures has promoted the use of friction stir welding (FSW) for welding dissimilar aluminum alloys. However, tensile residual stresses and microstructural heterogeneities often degrade weld integrity. This study investigates the combined impact of base material positioning, single- and double-pass FSW, and post-weld shot peening (SP) on the metallurgical and mechanical properties of AA6061–AA2017 joints. Five welding configurations were examined to evaluate how varying base material positions on the advancing and retreating sides affect material flow and mechanical behavior. Post-weld SP effectively presented compressive residual stresses, reduced surface defects, and refined surface grains. The average grain size in the stir zone was reduced from 5.2 μm (single-pass) to 2.0 μm (double-pass U-turn) after SP, confirming significant grain refinement through dynamic recrystallization. Mechanical testing
Nukathoti, Raja Sekhar, Battina, N. Malleswara Rao, Vanthala, Varaha Siva Prasad, Chirala, Hari Krishna, Maloth, Balu
Nickel Alloy, Corrosion- and Heat-Resistant, Bars, Forgings, Rings and Stock for Forgings, Rings and Heading, 72Ni - 15.5Cr - 0.95Cb - 2.5Ti - 0.70Al - 7.0Fe (Inconel® X750), Equalized, Precipitation HardenableAMS5667R (Current)4/13/2026
This specification covers a corrosion- and heat-resistant nickel alloy in the form of bars, forgings, flash-welded rings, and stock for forging, flash-welded rings, or heading.
AMS F Corrosion and Heat Resistant Alloys Committee
Steel, Corrosion- and Heat-Resistant, Sheet, Strip, and Plate, 15Cr - 25.5Ni - 1.2Mo - 2.1Ti - 0.006B - 0.30V (A286), Multiple Melted, 1800 °F (982 °C) Solution Heat Treated, Welding Grade, Precipitation HardenableAMS5858F (Current)4/13/2026
This specification covers a corrosion- and heat-resistant steel in the form of sheet, strip, and plate.
AMS F Corrosion and Heat Resistant Alloys Committee
Nickel Alloy, Corrosion- and Heat-Resistant, Sheet, Strip, and Plate, 45.5Ni - 25.5Cr - 3.2Co - 3.2Mo - 3.2W - 18.5Fe, (RA333®), Solution Heat TreatedAMS5593J (Current)4/13/2026
This specification covers a corrosion- and heat-resistant nickel alloy in the form of sheet, strip, and plate.
AMS F Corrosion and Heat Resistant Alloys Committee
Steel, Corrosion-Resistant, Investment Castings, 16Cr - 1.9Ni - 0.08N (431), As CastAMS5353G (Current)4/13/2026
This specification covers a corrosion-resistant steel in the form of investment castings.
AMS F Corrosion and Heat Resistant Alloys Committee
Titanium Alloy Bars, Wire, Forgings, and Rings, 6Al - 6V - 2Sn, AnnealedAMS4978K (Current)4/13/2026
This specification covers a titanium alloy in the form of bars, wire, forgings, flash-welded rings 4.000 inches (101.60 mm) and under in diameter or least distance between parallel sides, and stock of any size for forging or flash-welded rings (see 8.6).
AMS G Titanium and Refractory Metals Committee
Plastic Motor Vehicle Safety Glazing - Tolerances and Fabrication DetailsJ1691_202604 (Current)4/13/2026
This SAE Recommended Practice is intended to cover plastic safety glazing for use in motor vehicles and motor vehicle equipment. Nominal specifications for thickness, flatness, curvature, size, and fabrication details are presented principally for the guidance of body engineers and designers. For additional information on plastic safety glazing materials for use in motor vehicles and motor vehicle equipment, please refer to SAE J673.
Glazing Materials Standards Committee
Securing Child Restraint Systems in Motor VehiclesJ1819_202604 (Current)4/13/2026
The scope of this SAE Recommended Practice is to promote compatibility between child restraint systems and vehicle seats and seat belts. Design guidelines are provided to vehicle manufacturers for certain characteristics of seats and seat belts and to child restraint system (CRS) manufacturers for corresponding CRS features so that each can be made more compatible with the other. The CRS accommodation fixture (see Figure 1) is used to represent a CRS to the designers of both the vehicle interior and the CRS for evaluation of each product for compatibility with the other. The features of the accommodation fixture are described as each is used.
Children's Restraint Systems Committee
Steel, Corrosion-Resistant, Bars, Wire, Forgings and Forging Stock, 18.5Cr - 10Ni - 0.22Se (303Se), Free-Machining; for Swaging or Upsetting, Solution Heat TreatedAMS5641K (Current)4/13/2026
This specification covers a free-machining, corrosion-resistant steel in the form of bars, wire, forgings, and forging stock.
AMS F Corrosion and Heat Resistant Alloys Committee
Magnesium Alloy, Investment Castings, 8.7Al - 0.70Zn - 0.22Mn (AZ91C-T6), Solution and Precipitation Heat TreatedAMS4452G (Current)4/9/2026
This specification covers a magnesium alloy in the form of investment castings (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Rolled or Forged Rings, 5.6Zn - 2.5Mg - 1.6Cu - 0.23Cr (7075-T651, 7075-T652), Solution Heat Treated, Mechanically Stress Relieved, and Precipitation Heat TreatedAMS4310G (Current)4/9/2026
This specification covers an aluminum alloy in the form of rolled or forged rings up to 6 inches (152 mm), inclusive, in thickness (see 3.3.1.1.1) and an OD to wall thickness ratio of 10 or greater (see 8.5).
AMS D Nonferrous Alloys Committee
Steel Bars, Forgings, and Tubing, Nitriding, 1.4Cr - 1.2Mo - 0.3V (0.29 - 0.36C), (32CrMoNiV5), Double Vacuum Melted, Premium Aircraft-Quality for Bearing ApplicationsAMS6498C (Current)4/9/2026
This specification covers a nitriding grade of premium aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock. AMS6496 and AMS6497 cover UNS K23280 with other quality levels.
AMS E Carbon and Low Alloy Steels Committee
Steel, Sheet, Strip, and Plate, 0.75Si - 0.62Cr - 0.20Mo - 0.10Zr (0.10 - 0.17C) (NAX 9115-AC)AMS6354H (Current)4/8/2026
This specification covers a low-alloy steel in the form of sheet, strip, and plate 4.00 inches (101.6 mm) and under in thickness.
AMS E Carbon and Low Alloy Steels Committee
Aluminum Alloy, Sheet, 3.2Cu - 0.52Mg - 0.30Ag - 0.95 Li - 0.12Zr (2198-T8), Solution Heat Treated, Cold Worked, and Artificially AgedAMS4412C (Current)4/8/2026
This specification covers an aluminum alloy in the form of sheet from 0.063 to 0.249 inch (1.60 to 6.30 mm) in nominal thickness (see 8.6).
AMS D Nonferrous Alloys Committee
Copper Alloy (Brass), Sheet, Strip, and Plate, 70Cu - 30Zn, Half Hard (H02)AMS4507K (Current)4/8/2026
This specification covers a copper-zinc alloy (brass) in the form of sheet, strip, and plate (see 8.6).
AMS D Nonferrous Alloys Committee
Magnesium Alloy, Investment Castings, 9.0Al - 2.0Zn (AZ92A-T6), Solution and Precipitation Heat TreatedAMS4453H (Current)4/8/2026
This specification covers a magnesium alloy in the form of investment castings (see 8.6).
AMS D Nonferrous Alloys Committee
Test Method for Measuring Wet Color Transfer CharacteristicsJ1326_202604 (Current)4/8/2026
This procedure describes a method of measuring the resistance to wet color transfer of materials such as textiles, leather, and composites.
Textile and Flexible Plastics Committee
Characterization of a Low-Cost Insulator Substrate for Traction Power Modules2026-01-01194/7/2026
Demand for cost-effective automotive traction inverters requires improved power module packaging. This paper presents a packaging method using an epoxy composite insulator applied directly to the cold plate surface, replacing Direct Bonded Copper (DBC) and Active Metal Brazed (AMB) substrates. This integration removes the substrate-to-cold plate solder interface and eliminates two material layers from the thermal path. The epoxy composite demonstrates a dielectric strength greater than 60 kV/mm. Thermal resistance (junction-to-coolant) measured approximately 0.17 K∙cm2/W. Electrical characterization showed a relative permittivity of 3.9, which is lower than standard ceramics and results in reduced parasitic capacitance. Initial thermal cycling tests indicated no significant degradation in thermal or electrical performance. These results suggest the epoxy composite insulator could be a promising alternative for traction power modules.
Chen, Yu, Mena-Garcia, Javier, Chen, Hao, Xiao, Kewei, Gupta, Man Prakash, Degner, Michael
A Vehicle-Integrated Validation Method for Weather-Strip Sealing Performance in Automotive Closure Systems2026-01-02004/7/2026
Weather-strip sealing systems are critical to automotive closure performance, influencing water- and dust-tightness, aerodynamic noise control, and overall NVH quality. Conventional validation often relies on flat or straight JIG-based tests that inadequately represent the curved, angled, and non-uniform geometries of real closures such as doors, tailgates, hoods, roofs, and fixed or movable glass. This disparity limits the predictive accuracy of sealing performance in actual vehicles. This study proposes a vehicle-integrated validation framework that mirrors true geometric and contact conditions. The methodology combines finite element analysis (FEA) of both flat JIG and full-vehicle CAD geometries with experimental JIG tests, establishing a baseline for pressure distribution, compression load, and sealing contact behavior. A comparative analysis highlights significant deviations between flat-section predictions and vehicle-specific closure profiles. Results demonstrate that the
Ganesan, Karthikeyan, Seok, Sang Ho
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