Browse Topic: Composite materials

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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
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
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
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
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
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
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
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.
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
Kissing Bonds Inspection by Comparing Natural Frequencies Using Digital Holography2026-01-02074/7/2026
Accurate detection and evaluation of kissing bonds in composite materials is essential to ensure the integrity of the component structure, but traditional NDT (non-destructive testing) methods struggle to identify imperfect bonds and zero-volume debonds. In this study, a vibration analysis method based on holography was applied to detect kissing bonds by monitoring the changes in natural frequencies of the same sample before and after fatigue loading. Both pristine and kissing bond samples were tested under identical conditions, and their vibration characteristics (natural frequency, amplitude, and mode shape) were measured using holography. The experimental results show for the intact sample exhibited no changes in natural frequency amplitude or mode shape after fatigue loading, confirming that the applied fatigue test did not affect the integrity of its adhesive layer. In contrast, for the sample with a kissing bond, after fatigue loading, the natural frequency decreased by up to 22
Gao, Zhongfang, Fang, Siyuan, Gerini-Romagnoli, Marco, Yang, Lianxiang
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
High Strain Rate Behaviors of Fiber Reinforced Composites in Principal and Off-Axis Directions2026-01-01754/7/2026
Materials can exhibit significantly different mechanical behaviors compared to quasi-static conditions at high strain rates (> 100 s-1). High strain rate tests using setups such as SHPB (Split-Hopkinson Pressure Bar) can provide, in a practicable manner, the stress-strain relations for a material at high strain rates. Such properties are vitally needed for activities such as simulation-driven impact safety design of composite structures deployed in the form of automotive body parts and assembly, and other sub-systems. Although the behaviors of isotropic and ductile materials such as various metallic alloys appear to have been extensively studied and reported in literature, dependence of mechanical properties of fiber-reinforced composites especially in different off-axis directions are extremely difficult to come across. To fill up this void, a detailed experimental study has been carried out on high strain rate mechanical characterization of a laminated orthotropic glass/epoxy
Bawa, Prashant, Deb, Anindya, Barui, Ananya, Zhu, Feng
A Study on Fatigue Life Prediction Method for Point-Based Joints Considering Multiple Fracture Modes – FDS, Blind Rivet, and Blind Nut Focus2026-01-01804/7/2026
The application of multiple materials in vehicle bodies is accelerating as the adoption of lightweight aluminum alloys and composite materials advances rapidly. These materials play a crucial role in reducing overall vehicle weight, enhancing fuel efficiency, and complying with increasingly strict environmental regulations. As the automotive industry continues to evolve toward electrification and sustainability, the integration of lightweight and high-performance materials has become a key design strategy. However, the use of multiple materials creates new challenges in manufacturing, particularly for joining technologies. Since different materials have varying mechanical properties, thermal behavior, and surface characteristics, the selection of appropriate joining methods is essential for ensuring structural integrity and durability. Depending on material types, thicknesses, production processes, and cost constraints, various joining techniques—such as mechanical fastening, welding
Takuno, Sougo, Isono, Toshiyuki, Urakawa, Kazushi, Goto, Suguru, Kawamura, Hiroaki, Niisato, Eita, Ishigami, Yuta
Anisotropic Mechanical Property Simulation of Fiber Reinforced PEEK Using Composite Theory and Comparison to Experimental Results2026-01-02564/7/2026
The mechanical properties of 3D printed composites have been shown to vary due to the manufacturing infill direction due to artifacts from the printing process. PEEK (Polyether Ether Ketone) and PEEK reinforced with carbon fiber were studied for these experiments because they are widely used for their high strength properties. 3D printed composites that behave with anisotropic characteristics have been evaluated under Laminate Composite Theory (LCT), which can be used to determine the mechanical properties of these 3D printed composites. By changing the orientation of the extruded strands in a 3D printed part, the structure can be optimized in a specific orientation for specific loading conditions, and LCT can be applied for simulating mechanical responses. Three point bending tests were performed on rectangular 3D printed samples and compared to a 3D simulation using LCT for a similar bending load. This allows for the use of LCT in combination with a finite element software such as
Bradley, Coilin, Garcia, Jordan, Sibley, Brian
Development of an Advanced Tensile Testing Method for HDPE Composites in High Draw Molded Hollow Circular Regions: Effect of Sample Preparation, Asymmetry, Thermal Conditions, Pull Speeds and Fixture Parameters2026-01-02044/7/2026
High-Density Polyethylene (HDPE), Low-Density Polyethylene (LDPE) and Ethylene Vinyl Alcohol (EVOH) composite, particularly in high draw molded hollow circular configuration, present unique challenges in evaluating mechanical performance under tensile stress due to anisotropic deformation, geometric asymmetry, and localize thermal gradient. This study introduces an advanced tensile testing methodology designed specifically to assess such regions with greater precision and reproducibility. The method incorporates refines sample preparation protocols, tailored fixture geometry, and adjustable pull speed to accommodate varying thermal histories and draw ratios inherent to molded sections. Systematic variation of asymmetrical, temperature conditions, and clamping techniques revealed significant impact on tensile strength, elongation at break, and strain distribution. Findings emphasize the necessity of customized testing frameworks for molded composites geometries and demonstrate that
Bhalerao, Saurabh Shankar
Multi-Objective Topology Optimization for Cost and Time Minimization in Fiber Reinforced Additive Manufacturing2026-01-02574/7/2026
Fiber Reinforced Additive Manufacturing (FRAM) combines the geometric freedom of additive manufacturing with the high stiffness-to-weight advantages of composite materials, making it a promising approach for lightweight automotive components. The mechanical performance of fiber-reinforced composites is strongly influenced by fiber orientation, which highlights the importance of optimization methods that can effectively exploit anisotropic behavior. Existing FRAM optimization research has focused primarily on structural performance and has given limited attention to manufacturability challenges. This gap is significant, as overhangs and the resulting need for support structures can substantially increase print time, material consumption, and production cost, restricting broader industrial uptake. This research introduces a multi-objective topology optimization framework that incorporates Design for Additive Manufacturing (DfAM) principles by minimizing both structural compliance and
Wotten, Erik, Kim, Il Yong
Modification of Composite Cathode for Sulfide-Based All-Solid-State Batteries2026-01-70372/27/2026
All-solid-state batteries (ASSBs) based on sulfide electrolytes hold great promise for next-generation energy storage, yet their performance is critically constrained by unstable cathode–electrolyte interfaces. Here, we report a dual-modification strategy utilizing ionic liquids (ILs) in combination with lithium salts to simultaneously improve interfacial wettability, ionic transport, and electrochemical stability in NCM811 composite cathodes. Three ILs (EMIMTFSI, Pyr₁₄FSI, and PP₁₃FSI) and three lithium salts (LiTFSI, LiDFOB, and LiBOB) were systematically evaluated and screened. While neat ILs improved initial capacities by reducing solid–solid contact resistance, they also triggered parasitic reactions with sulfides, resulting in capacity fading. Among the lithium salts, LiBOB was identified as the most chemically compatible additive, forming thin and uniform hybrid interphases enriched with B–O species. This interphase effectively suppressed high-voltage side reactions and reduced
Gu, Yu-Yang, Tian, Shi-Yu, Qi, Ji, Yang, Li-Peng, Zhan, Wen-Wei, Yang, Xiao-Guang, Yi, Yong
Composite Current Collectors and Aramid Separator Enabled Safer High-Nickel Batteries2026-01-70322/27/2026
The requirement on high energy density Li-ion batteries demands high energy chemistry system, this rise concerns on batteries’ safety issue. Battery non-active components, including current collectors and separator play important role in improving battery safety. Composite current collectors, which are consisted of a polymer layer between two plated thin metal layers, are widely treated as a solution to reduce safety concerns caused by high nickel layered cathode materials, e.g. LiNi1-x-yCoxMnyO2, LiNi1-x-yCoxAlyO2 and LiNi1-x-y-zCoxMnyAlzO2 with Ni content higher than 0.8. In the meantime, composite current collectors can reduce most weight of current collectors and improve the cell’s gravimetric energy density without replacing cathode or anode materials. Moreover, high thermal stable separator could effectively prevent internal short circuit for it melts in higher temperature. In this work, we came up with a cell design which contains composite current collectors as positive
Liu, Jingyuan, Lu, Yong, Liu, Haijing
Teaching Points for a Class on “Critical Issues in Composite Maintenance, Repair, and Overhaul”AIR5719B (Current)2/13/2026
This document is to be used as a checklist by curriculum developers to create courses or training for critical composite repair, maintenance, and overhaul issues. This document will not take the place of courses or training requirements for specific job roles of a composite repair technician, inspector, or engineer.
AMS CACRC Commercial Aircraft Composite Repair Committee
Effect of Sebastiana Rostrata Fiber Loading on the Tribological Behaviour of Polycaprolactone Biocomposite2026-28-00212/12/2026
This study investigates the tribological behaviour of Sesbania rostrata fiber (SRF) reinforced polycaprolactone (PCL) biocomposites using a pin-on-disc wear couple. The stationary SRF/PCL composite specimen interacted with a rotating EN31 steel disc (64 HRC), establishing the sliding wear interface in accordance with ASTM G99 standards. Composite laminates containing 10, 20, and 30 wt% SRF were evaluated at a sliding velocity of 1 m/s over a fixed distance of 1000 m under varying normal loads. The incorporation of SRF significantly enhanced the wear performance relative to neat PCL, with 20 wt% fiber loading achieving the lowest coefficient of friction and specific wear rate due to improved load transfer, stronger interfacial adhesion, and a more uniform laminate structure. In contrast, the 30 wt% composite exhibited fiber agglomeration, reduced homogeneity, and weakened fiber–matrix interactions, resulting in increased wear. SEM microstructural analysis confirmed the formation of a
Raja, K., Senthil Kumar, M.S.
Modelling and Analysis of Complex Shaped Cracks2026-28-00482/12/2026
This study provides an extensive analysis through finite element analysis (FEA) on the effects of fatigue crack growth in three different materials: Structural steel, Titanium alloy (Ti Grade 2), and printed circuit board (PCB) laminates based on epoxy/aramid. A simulation of the materials was created using ANSYS Workbench with static and cyclic loading to examine how the materials were expected to fail. The method was based on LEFM and made use of the Maximum Circumferential Stress Criterion to predict where cracks would happen and how they would progress. Normalizing SIFs while a crack was under mixed loading conditions was achieved using the EDI method [84]. We used Paris Law to model fatigue crack growth using constants (C and m) for the materials from previous studies and/or tests. For example, in the case of titanium Grade 2, we found Paris Law constants with C values from 1.8 × 10-10 to 7.9 × 10-12 m/cycle and m values from 2.4 to 4.3, which illustrate differing effects of their
T, Lokesh, Bhaskara Rao, Lokavarapu
Vibrational Analysis of Hybrid Composite Laminated Plates of E – Glass and Areca Fibers with Brake Pad Waste Powder2026-28-00732/12/2026
This study focuses on the vibration analysis of hybrid composite laminated plates fabricated from E-glass Fiber and areca Fiber reinforced with epoxy resin. The hybrid laminates were prepared using the Vacuum Assisted Resin Transfer Moulding (VARTM) process with different stacking sequences and Fiber ratios, where brake lining powder was also incorporated as a filler in selected configurations to enhance mechanical and damping properties. The fabricated plates (280 × 280 mm) were subjected to experimental modal analysis using an impact hammer and accelerometer setup, with data acquisition carried out through DEWESoft software. Natural frequencies and damping ratios were determined under three boundary conditions (C- C-C-C, C-F-C-F, and C-F-F-F). The results revealed that Plate 1, with E-glass outer layers, areca reinforcement, and filler addition, exhibited the best vibration performance, achieving a maximum natural frequency of 332.8 Hz under C-C-C-C condition, while Plate 2 showed a
D R, Rajkumar, O, Vivin Lenin, R, Saktheevel, R G, Ajay Krishna, Ng, Bhavan
Genetic Algorithm Based Optimization of Chaboche Kinematic Hardening Parameters along with the Validation of FE Model through Characterized Crack Initiation2026-28-00862/12/2026
In the context of electro-mobility for commercial vehicles, the failure analysis of a connector panel in a DCDC converter is crucial, particularly regarding crack initiation at the interface of busbar and plastic component. This analysis requires a thorough understanding of thermo-mechanical behavior under thermal cyclic loads, necessitating kinematic hardening material modeling to account for the Bauschinger effect. As low cycle fatigue (LCF) test data is not available for glass fiber reinforced polyamide based thermoplastic composite (PA66GF), we have adopted a novel approach of determining non-linear Chaboche Non-Linear Kinematic Hardening (NLK) model parameters from monotonic uniaxial temperature dependent tensile test data of PA66GF. In this proposed work a detailed discussion has been presented on manual calibration and Genetic Algorithm (GA) based optimization of Chaboche parameters. Due to lack of fiber orientation dependent test data for PA66GF, here von Mises yield criteria
Basu, Parichay, Srinivasappa, Naveen
Aerospace & Defense Technology: February 202626AERP022/5/2026
Plasma Surface Activation for Stronger, More Durable CFRP Bonds in Aerospace Smarter Pyrovalve Alternatives for Modern Missile and Munition Launcher Applications Aerospace Aluminum Laser Welding: Advancing Material Performance for the Future of Flight Model-Based Design Is Shaping the Next Phase of eVTOL Systems Development How RF-over-Fiber is Providing the Backbone of Next Generation Mil/Aero Networks NASA Demonstrates a First-of-Its-Kind Space Communications A Rainfield Simulator for Hypersonic Testing The U.S. Army Space and Missile Defense Command Technical Center's Aerophysics Research Facility, (ARF), fired a successful hypersonic shot to test its new rainfield simulator. Next Generation Carbon Fiber Composites 3D Printer for Hypersonic Research Auburn University's Applied Research Institute in Huntsville is adding some serious fiber to its diet. The Critical Impact Of SAE Aerospace Standards: Certified AS1895/7 and /23 Metal Seals How engineers can ensure safety, reliability
Next Generation Carbon Fiber Composites 3D Printer for Hypersonic Research26AERP02_082/1/2026
Auburn University's Applied Research Institute in Huntsville is adding some serious fiber to its diet. Auburn University, Auburn, AL In collaboration with Auburn University's Center for Polymers and Advanced Composites (CPAC) and the Department of Aerospace Engineering, the institute recently acquired a CF3D Enterprise Cell - a next-generation 3D carbon fiber composites printer set to define the future of the nation's hypersonic programs. Developed by Idaho-based Continuous Composites, the CF3D system represents a highly specialized advanced manufacturing capability and is the only system of its kind currently operating in Alabama.
Aerospace Aluminum Laser Welding: Advancing Material Performance for the Future of Flight26AERP02_032/1/2026
Between the 1920s and 1930s, aluminum started replacing wood as the primary material in aircraft construction and soon became the backbone of modern aviation. Its popularity stemmed from a combination of properties, high strength-to-weight ratio, corrosion resistance, and ease of forming that made it ideal for demanding aerospace applications. Throughout much of the 20th century, high-strength aluminum alloys dominated aircraft design, accounting for 70-80 percent of commercial airframes and more than half of many military aircraft. Even after the introduction of fiber-polymer composites in the early 2000s, aluminum has remained a critical material because it continues to offer the strength, lightness, and versatility needed for modern aviation. Industry forecasts predict that commercial air travel will double in the next 25 years, which means more pollution will be released into the atmosphere. One way to help reduce these emissions is by building airplane fuselages and wings with
Plasma Surface Activation for Stronger, More Durable CFRP Bonds in Aerospace26AERP02_012/1/2026
Carbon fiber-reinforced polymers (CFRPs) have become essential in modern aerospace structures, from fuselage skins and wing components to nacelles, interior structures, and a growing range of primary load-bearing parts. Their high strength-to-weight ratio delivers major benefits in fuel efficiency, payload capacity, and fatigue performance. Yet achieving reliable adhesive bonds on CFRP surfaces remains a persistent engineering challenge. The low intrinsic surface energy of composites - particularly under thermal cycling, vibration, and moisture exposure - limits bond durability unless surfaces are properly prepared. Plasma surface treatment has emerged as a pivotal solution, offering a fast, controllable, and non-destructive way to increase surface energy, improve wettability, and enhance adhesion across complex geometries. This is especially important as the aerospace industry transitions from thermoset to thermoplastic composites (TPCs), which enable faster processing, lower
Design and Development of a Lightweight Aluminium Cascade System for Type IV COPVs for Stationary and Mobile Applications2026-26-04851/16/2026
The global push for clean energy has made hydrogen a central element in decarbonizing transport, industrial processes, and energy systems. Effective hydrogen storage and distribution are critical to supporting this transition, and type IV Composite Overwrapped Pressure Vessels (COPVs) have emerged as the preferred solution due to their lightweight, high pressure capacity, hydrogen embrittlement and corrosion resistance. However, the cascade infrastructure used to house and transport these vessels has lagged behind in innovation. Steel-based cascades, while strong, are heavy prone to corrosion, and unsuitable for mobile deployment. This paper introduces a custom designed aluminium cascade system offering a 65% weight reduction while maintaining structural integrity and safety. Designed for mobile use, the system features modularity, better damping, and enhanced corrosion protection. The paper outlines design methodology, material selection, fabrication process, and comparative
Parasumanna, Ajeet Babu, Muthusamy, Hariprasad, Ammu, Vnsu Viswanath, Kola, Immanuel Raju
Bioadhesive Sponge Stops Internal BleedingTBMG-544071/1/2026
Researchers combined mussel adhesive protein with decellularized extracellular matrix (dECM) to develop a composite hemostatic sponge that offers both strong tissue adhesion and biocompatible biodegradability.
Study on the Influence of Liquid Composite Swivel Arm Positioning Nodes on the Dynamic Performance of High-Speed Trains2025-99-025512/23/2025
Rubber components are an important part of the suspension system of high-speed trains, and the complex nonlinear characteristics of rubber parts have a significant impact on the vehicle dynamic performance. This paper establishes a nonlinear dynamics model of the liquid composite swivel arm positioning node, which can reflect the dynamic stiffness and dynamic damping characteristics of the rubber components that change nonlinearly with the frequency and amplitude, and also has a fast calculation speed. The vehicle dynamics simulation model considering the longitudinal stiffness nonlinear characteristics of the arm node is established, and the influence of the stiffness nonlinearity of the liquid composite arm positioning node on the dynamic performance of the vehicle, such as straight-line stability and curve passing ability, is studied in depth through numerical simulation.
Cheng, Junqiang, Yang, Chen, Li, Longtao, Cong, Rilong, Hu, Tingzhou
Biocomposite of Euterpe oleracea Mart and Cocos nucifera l. : Sustainable Materials2025-36-016312/18/2025
Brazil is recognized for its vast biodiversity and abundance of natural resources, many of which are still underutilized. In an effort to promote sustainability and innovation, there is a growing movement to replace non-recyclable materials with ecological alternatives. Within this context, acai leaves (Euterpe oleracea Mart.) and coconut leaves (Cocos nucifera L.) appear as potential natural reinforcements in polymer composites. This study aims to evaluate the mechanical properties of composites formed by these sheets, using polyester resin as the matrix phase. Tensile strength tests were conducted on specimens, following the ASTM D 638M standard, to determine the mechanical properties of the composites. The results obtained were compared with data from the existing literature in order to validate the effectiveness of the composites produced. Additionally, fractures in the specimens were visually analyzed for a better understanding of the failure mechanisms.
Dias, Roberto Yuri Costa, Santos Borges, Larissa, Brandao, Leonardo William Macedo, Mendonca Maia, Pedro Victor, Silva de Mendonça, Alian Gomes, Fujiyama, Roberto Tetsuo
Injection Molding Parameters Optimization to Enhance Mechanical Properties of Glass-Fiber Reinforced PA9T Polymer2025-36-012412/18/2025
The use of polymeric materials and polymer -based composites as alternatives to metals in conventional applications is a widely adopted strategy. These materials provide advantages in terms of processability, cost-effectiveness, and, most notably, weight reduction. This study aimed to develop and optimize the injection molding process for producing PA9T (Polyphthalamide 9T) components reinforced with varying amounts of glass fiber to achieve optimal mechanical and physical properties. To enhance mechanical performance, different glass fiber loadings were investigated. The study employed the Taguchi method with an L9 orthogonal array design. The selected variable parameters were material composition (PA9T reinforced with 30, 35, and 50 wt% glass fiber), injection pressure (1000, 1500, and 2000 bar), injection temperature (320, 330, and 340 °C), and injection speed (100, 125, and 150 mm/s). The Taguchi method was chosen because it allows for the identification of optimal process
Mendonça, Arthur S., Michelotti, Alvaro Canto, Berto, Lucas F., Salvaro, Diego B., Binder, Cristiano
Influence of the PTFE on the Tribological and Mechanical Properties of a Fiber-Reinforced Polyphthalamide2025-36-022112/18/2025
Materials science and engineering are essential for advancing energy-efficient mechanical systems through lightweight structures and friction reduction. Among engineering polymers, polyphthalamides (PPA) are widely used for their superior thermochemical and mechanical properties. This study investigates the influence of polytetrafluoroethylene (PTFE) on the mechanical and tribological performance of a commercial polymer matrix composite (PMC) reinforced with 30wt% glass fiber. Self-lubricating composites were manufactured by injection molding with PTFE contents ranging from 0-15 wt%. Density was measured using Archimedes’ method. Mechanical properties were measured through ISO 527 tensile testing, while tribological behavior was evaluated using ball-on-flat reciprocating tests under 189N (630 MPa), 2 H frequency, and 10 mm strokes for 60 minutes, employing a 10 mm diameter AISI 52100 steel sphere as counter-body. Friction coefficient (COF) was monitored throughout testing, and wear
Hromatka, Matheus, Salvaro, Diego B., Binder, Cristiano, Michelotti, Alvaro C., Berto, Lucas F.
Natural Fibers Applied in the Automotive Industry in Brazil: A Review2025-36-017012/18/2025
There is a growing demand for new materials that meet mechanical and structural performance requirements, with specific properties, especially in the automotive industry. From a context of innovation and global needs to be met, there is the appreciation of composite materials, specifically applied in the automotive sector, since these can be obtained from the combination of two or more different materials, obtaining certain properties from the individual characteristics of its phases, expanding the availability of materials to be used in this sector. In recent years the use of natural fibers in composite materials for automotive applications has gained relevance due to factors such as sustainability, low weight and good mechanical properties. The attempt to combine innovation and environmental preservation make such applications promising, aiming to obtain ecological solutions, considering that natural fibers of vegetable origin such as sisal, jute and flax are biodegradable and
Dias, Roberto Yuri Costa, Santos Borges, Larissa dos, Brandao, Leonardo William Macedo, Mendonca Maia, Pedro Victor de, Silva de Mendonça, Alian Gomes da, Fujiyama, Roberto Tetsuo
Mechanical Tensile Behavior of Polyester Composites with Addition of Banana and Sugarcane Fibers2025-36-015412/18/2025
Polymer composites with the addition of natural fibers have gained prominence as a sustainable and technically viable alternative to conventional synthetic materials, especially in applications that require a balance between mechanical performance and environmental responsibility. This study evaluated the mechanical behavior of composites produced with plant fibers from banana (Musa sapientum) and sugarcane (Saccharum officinarum L.), both sourced from the northern region of Brazil. The fibers, used in their natural state without chemical treatment, were cut to a uniform length of 5 mm for standardization. The polymer matrix used was unsaturated terephthalic polyester resin, pre-accelerated and catalyzed with methyl ethyl ketone peroxide (MEKP). The molding of test samples was performed manually in silicone molds, according to ASTM D638 specifications, to ensure repeatability and comparability of results. The mechanical tests revealed that the composites made with sugarcane fibers had
Santos Borges, Larissa, Dias, Roberto Yuri Costa, Brandao, Leonardo William Macedo, Mendonca Maia, Pedro Victor, Silva de Mendonça, Alian Gomes, Fujiyama, Roberto Tetsuo
Synergistic Effects of Graphene Oxide and Nanoclay on the Structural and Electrical Properties of Automotive Nanocomposite Insulation2025-36-016112/18/2025
As vehicles become increasingly connected and electrified, the demand for high-performance cables and electrical connectors is growing quickly. Electrical insulation materials play an essential role in protecting and insulating those critical components, ensuring reliability, safety and durability. The development of a more robust composite material is essential to promote sustainability and energy efficiency, in both component application and its manufacturing processes. This research explores the development of advanced nanocomposite material for automotive electrical applications. The nanocomposite material comprises low-density polyethylene (LDPE), ethylene-vinyl acetate (EVA), nanoclay (NC) and graphene oxide (GO), processed via melt mixing in a twin-screw extruder. A design of experiments (DOE) was performed using 23, factorial design two levels and three variables (wt.% of EVA, NC and GO), to evaluate the effect of each variable on the material performance. Mechanical tests
Horiuchi, Lucas Nao, Kerche, Eduardo Fischer, Gonçalves, Everaldo Carlos, Polkowski, Rodrigo
Natural Fiber Composites with Nanomaterials: A Sustainable Alternative to Metals in the Automotive Industry2025-36-004012/18/2025
This paper analyzes the potential of combining natural fibers with nanomaterials to develop advanced composites for automotive sector applications, providing a sustainable alternative to parts traditionally produced with metallic materials. The metallic alloy in the automotive industry is widely used in vehicle manufacturing, but faces significant challenges, such as high production costs, high weight, susceptibility to corrosion, and rigorous recycling processes. Natural fibers stand out for favorable mechanical properties, low cost, low weight, and eco-friendly material, making promising alternatives to metals and synthetic fibers. The combination of natural fibers and nanomaterials creates composites with improved mechanical and thermal, reducing any limitations inherent to natural fibers. Therefore, composites combined, called hybrid, have a high potential for use in various automotive components, such as in structural and non-structural applications. This study also analyzes the
Corrêa, Karytha, Cabral, Gabriel, Santiago, Marcelo, Veloso, Verônica, Chaves, Matheus
Review of Through-the-Thickness Reinforcement Technologies Applied to Aircraft CFRP Composites2025-99-035512/17/2025
Carbon fiber-reinforced polymer (CFRP) composites are widely used in aircraft structures for weight reduction due to their high specific strength and modulus. However, their weak interlaminar properties lead to high sensitivity to out-of-plane loads such as impact, making them prone to delamination damage, which threatens flight safety. To enhance interlaminar performance, through-thickness reinforcement technologies, particularly Z-pinning and stitching, have become key research focuses. This paper systematically reviews the manufacturing processes, structural mechanical characteristics, and application progress in aerospace structures of these two mainstream through-thickness reinforcement technologies. Research shows that Z-pintechnology, by implanting metal or CFRP pins, and stitching technology, by sewing multiple fabric layers with fiber threads, both effectively bridge interlaminar cracks, significantly improving the impact resistance of composites. However, the implantation
Cui, Bo, Zhang, Yongjie, Zhang, Chuzhe, Jin, Tao
Mechanical System Innovation for Next-Generation Electric Vehicles: Lightweight and Energy Recovery Co-Design2025-99-033412/17/2025
Aiming at the technical bottlenecks of electric vehicles (EVs) in terms of range, energy efficiency and thermal management, this paper proposes an innovative mechanical system design scheme that integrates lightweight materials, topology-optimised structure and mechatronic energy recovery. Through multi-physics simulation and experimental verification, the coupling mechanism between mechanical design and electrochemical performance is revealed, providing theoretical support for the development of energy-efficient electric vehicles. The research adopts a hybrid structure of carbon fiber reinforced polymer (CFRP) and aluminum alloy, and combines it with topology optimization technology to achieve lightweight (18% weight reduction) and improved impact resistance (40% improvement in energy absorption) of the battery box; the design of a bimodal energy recovery system integrating flywheel energy storage and magnetorheological damper, which can achieve an energy recovery efficiency of 82.7
Xu, Nanxin, Song, Ziyang, Han, Qiyu, Chen, Xiaoxian, Miao, Zhengchen, Song, Jinlong
Carbon Fiber and Fiberglass Epoxy Prepreg Products with 350 °F (177 °C) Cure for Aerospace ApplicationsAMS6891A (Current)12/16/2025
The intent of this specification is for the procurement of carbon fiber and fiberglass epoxy prepreg products with 350 °F (177 °C) cure for aerospace applications; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the production quality assurance section (4.3) of this base specification, AMS6891.
AMS P17 Polymer Matrix Composites Committee
Micromachining through Ultrasonic-Assisted Electrochemical Discharge Process: A Review05-19-03-002112/3/2025
As demand for microcomponents has escalated in diverse areas of automotive, medicine, communications, electronics, optics, biotechnology, and avionics industries, there is a need for hybrid manufacturing techniques that can effectively micromachine hard and brittle materials. Electrochemical discharge machining (ECDM) is an advanced manufacturing process for machining difficult-to-cut materials. With a need for precision and accuracy, tool kinematics is a potential research area in ECDM for achieving geometrical dimensioning and tolerances (GD&T). Therefore, the present study reviews the ultrasonic vibration–assisted ECDM (UA-ECDM) hybrid process and the performance of its process parameters (voltage, electrolyte type and its concentration, electrode material, pulse duration, and amplitude) on the material removal rate (MRR), tool electrode wear (TEW), surface integrity, and difficult-to-cut materials. Also, the present work mentions current problems (debris and bubbles trapped
Prajapati, Mehul S., Lalwani, Devdas I.
Carbon Fiber and Fiberglass Epoxy Prepreg Products with 350 °F (177 °C) Cure for Aerospace Applications: Type 35, Class 1, Grade 191AMS6891/1A (Current)12/1/2025
The intent of this specification is for the procurement of the material listed on the QPL; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the Quality Assurance section of the base specification, AMS6891.
AMS P17 Polymer Matrix Composites Committee
Automated fiber placement with Ramy Harik25AUTP12_0912/1/2025
AFP can build complex, lightweight structures, but cost concerns keep its use in the automotive industry to a minimum. For now, anyway. Ramy Harik, a Fulbright alumnus and director of the Clemson Composites Center, is pushing the boundaries of manufacturing with his latest book, Automated Fiber Placement: Status, Challenges, and Evolution coauthored with Alex Brasington. The book, published by SAE in June of 2025, serves as a comprehensive guide to automated fiber placement (AFP), a cutting-edge technology crucial for building complex, lightweight structures in the aerospace and automotive industries. The book aims to offer a thorough understanding of AFP's transformative potential for students, engineers, and industry professionals. The book synthesizes a decade of research, explaining how AFP supports the rise of advanced air mobility and sustainable structures for commercial and defense aircraft, space habitats, and beyond.
Blanco, Sebastian
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