Browse Topic: Advanced composite materials

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Structural Design and Simulation Study of Carbon Fiber Electronic Enclosures for Vehicles2026-99-01607/31/2026
Carbon Fiber Reinforced Polymer (CFRP), as an advanced lightweight structural material, exhibits significant application potential in the protection of electronic devices under extreme vehicle-mounted conditions due to its excellent specific strength and specific stiffness, superior energy absorption capacity, and unique damping and vibration reduction properties. This study closely integrates the characteristics of the complex and variable service environment in vehicles and adheres to the principle of equivalent stiffness matching to conduct innovative design explorations for electronic enclosures made of CFRP. To comprehensively evaluate the dynamic strength performance of CFRP vehicle-mounted enclosures under vibration and impact conditions, in-depth and detailed analyses were conducted using ANSYS software to simulate the power spectral density curves of random vibrations and the loading of post-peak sawtooth waveforms. The results indicate that the carbon fiber enclosure not only achieves remarkable weight reduction but also fully meets the requirements of environmental adaptability standards for automotive equipment. This achievement provides theoretical support and technical guidance for the engineering application of CFRP in the field of vehicle-mounted electronic devices and holds significant engineering application value for promoting the lightweight development of transportation equipment.
Zhang, Shuhui, Ma, Qihua
Research on the Influence of Ultrasonic Vibration on VARTM of CFRP2026-99-08447/30/2026
Due to their high specific modulus and specific strength, carbon fiber reinforced polymer (CFRP) composites have been widely adopted in the aviation field. However, CFRP components produced by conventional vacuum assisted resin transfer molding (VARTM) often exhibit defects such as Pores and dry spots. To address these limitations, this study develops a large-area, highly uniform vibration-assisted VARTM (UAVR) system and conducts ultrasound-assisted experiments. The results demonstrate that ultrasonic treatment at various frequencies consistently improves moulding uniformity. In particular, when the ultrasound frequency is 22 kHz, the tensile strength increases by up to 13.23%, and the compressive strength increases by up to 8.48%. This study has practical significance for improving the performance of CFRP.
Fang, Kaifa, Sun, Ruqian, Song, Gaoke, Zhang, Shuo, Cheng, Liqiang, Ma, Liping, Ruan, Benshuai, Xie1, Jiaqing
Research on the Fabrication of Composite Lattice by the Expandable Mold Method2026-99-16497/24/2026
Advanced composite materials have garnered widespread attention in the aerospace and other fields with stringent weight requirements, owing to their superior properties, such as lightweight, high strength, high modulus, and corrosion resistance. Compared with traditional metal materials, advanced composite materials can reduce structural weight by 30%. Lattice structures possess unique characteristics, including high designability, low cost, and high damage tolerance. As a specialized reinforced structure, they have been identified as one of the key structural configurations for next-generation aircraft. Composite lattice structures, which integrate the advantages of composite materials and lattice architectures, provide an ideal structural material for achieving lightweight and multifunctional aerospace equipment. However, due to the intricate geometries and diverse functional design requirements of lattice structures, the fabrication of these structures presents significant challenges, and there is an increasing amount of research on improving the accuracy and performance of composite lattice structures. The expandable mold process represents an approach for manufacturing composite lattice structures, where pneumatic pressure from rubber expansion enables consolidation of the lattice assembly during elevated-temperature curing to achieve the finished composite part. This study reviews composite lattice structures, verifies the feasibility of using rubber as an expansion mold by investigating the thermal stability and expansion properties, and then prepares composite lattice structures via the expandable mold technique. Additionally, composite lattice structures are prepared using laminated machining, an interlocking process, and a 3D printing process. The advantages and disadvantages of different process methods for forming composite lattice structures are compared, and finally, the future trends in high-performance lattice development are discussed.
Han, Shuhao, Lv, Zhen, Ma, Cheng, Xiu, Zhifeng, Song, Yanhua
Carbon Fiber and Fiberglass Epoxy Prepreg Products with 350 °F (177 °C) Cure for Aerospace ApplicationsAMS6891B (Current)7/13/2026
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 (see 4.3) of this base specification, AMS6891.
AMS P17 Polymer Matrix Composites Committee
Carbon Fiber Fabric Repair Prepreg, 120 °C (250 °F) Vacuum Curing, Part 3 - Purchasing Specification for Carbon PrepregAMS3970/3B (Current)7/13/2026
This Purchasing Specification (PS), AMS3970/3, specifies the batch release and delivery requirements for carbon fiber fabric epoxy prepreg used for repair. This specification is applicable only when the carbon fiber fabric epoxy prepreg is used as part of the repair system defined in AMS3970 and AMS3970/1. This specification also defines the procedure and requirements for storage life extension of materials purchased against this specification. It is only applicable for materials that are qualified against AMS3970 (refer to PRI QPL AMS3970) and shall be carried out within the responsibility of the purchaser and under control of its Quality organization.
AMS CACRC Commercial Aircraft Composite Repair Committee
Carbon Fiber Fabric Repair Prepreg, 120 °C (250 °F) Vacuum Curing, Part 5 - Purchasing Specification for Companion Non-Structural Glass Fiber Fabric PrepregAMS3970/5A (Current)7/13/2026
This Purchase Specification (PS), AMS3970/5, specifies the batch release and delivery requirements for the companion non-structural glass fiber fabric prepreg. This specification also defines the procedure and requirements for storage life extension of materials purchased against this specification. It is only applicable for materials which are qualified and shall be carried out within the responsibility of the purchaser and under control of its Quality organization.
AMS CACRC Commercial Aircraft Composite Repair Committee
Conceptual Design of CFRP Sandwich Structures Interfacing Cryogenic Tankages in Rockets2026-26-07616/1/2026
The study proposes the use of Carbon Fiber Reinforced Plastic (CFRP) sandwich composites configurations for structures interfacing cryogenic tankages. To address the design challenge posed by high thermal contractions in metallic tanks after cryogenic propellant filling, the study incorporates slits near the tank interfaces. Additionally, to minimize the transfer of cryogenic temperatures into these interfacing parts, the sandwich structure features interface end attachment made of thermally insulating Glass Fiber Reinforced Plastic (GFRP) material. Analytical and Finite Element (FE) studies were conducted on a typical cylindrical cryogenic intertank structure to demonstrate the proof of concept. These studies included analytical design using MATLAB based codes, parametric analyses with simplified shell element models and detailed 3D sector models using solid elements. The parametric studies assessed the effects of the number and dimensions of slits to achieve an optimal design, while the detailed 3D sector model provided refined results, validating the adequacy of the proposed concept. Proof-of-concept investigations on the case study sandwich intertank structure demonstrate a notable 30% improvement in mass efficiency compared to the truss configuration and 45% improvement relative to the closed shell metallic configuration, thereby validating the mass efficiency of the proposed design configuration.
Bhalerao, Sandesh Popat, Gupta, Yogesh Kumar, Madhukumar, P.
Thermal Management System in Commercial Aircraft: A Case Study on Passenger Egress System2026-26-07606/1/2026
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 protection materials on passenger Egress system utilized to mitigate pyrotechnic events. The focused case study on passenger egress system highlights a unique application of thermal protection. As these system, as mandated by FAA TSO-C69c, must ensure the system remains deployable and structurally stable for at least 90 seconds under intense heat exposure, preserving a workable egress path for passengers. The passenger egress system surface functions as a heat resistance barrier, resisting thermal energy from potential post-crash jet fuel fire. The heat barrier materials are polymer coated with woven nylon, impregnated with a metallic/ Ceramic layer. This study will emphasize how tailored material coating solutions are fundamental to addressing the diverse and extreme thermal demands in aerospace design, directly contributing to passenger’s safety and aircraft survivability.
Govindaraju, Parthasarathy, Nanjundegowda, Harshavardhana
Wear Resilience Characteristics of Silicon Nitride Strengthened AZ31 Magnesium Composite2026-26-07406/1/2026
To develop magnesium matrix composites, ceramic silicon nitride (Si3N4) particles are added to the magnesium (AZ31) matrix at 2 wt.%. The composite is produced via disintegrated melt deposition vacuum-stir-casting procedure. Microstructural studies reveal the presence of Si3N4 particles and their uniform spreading. An L9 orthogonal array, planned using Taguchi’s experimental design, is selected for three wear parameters; axial load (AL), rotational speed (RS), and time duration (TD) with trials as per the G99 standard in the pin-on-disc apparatus to assess the wear resilient of the composite. Experimental results show an increase in axial stress, and wear loss (WL) increases dramatically. Because the area of contact shrinks as RS increases, WL diminishes dramatically. When the AL is low, the friction coefficient (CoF) increases, and when the AL is large, CoF drops. When the RS is increased, CoF decreases. To optimize multiple responses effectively, the TOPSIS (Technique for Order Preference by Similarity to Ideal Solution) approach was adopted. According to the analysis, the ideal combination turned out to be a 10 N A, an RS of 275 rpm, and a TD of 1000 seconds. ANOVA results show that AL (56.99%) and RS (27.2%) contribute more, with a regression coefficient of 92.99%. Abrasive and adhesive wear mechanisms are observed from the worn-out surface micrographs.
Senthilkumar, N., Dhinakar Raj, C K
Advanced Composites Prepreg - Nominal 250 °F (121 °C) Cure - 12K Tow Carbon Fiber and Epoxy Resin, Plain Weave FabricAMS3914B (Current)5/15/2026
The intent of this specification is for the procurement of plain weave fabric epoxy prepreg product with 250 °F (121 °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 (see 4.3).
AMS P17 Polymer Matrix Composites Committee
Leveraging Ceramic Matrix Composites (CMCs) for Enhanced Performance in Engine Exhaust and Hot Aero StructuresF-0082-2026-01455/5/2026
This paper discusses the results of the trade study conducted under the Army ManTech-sponsored CH-47 Ceramic Matrix Composite Exhaust Duct Manufacturing Development Program. The program established a baseline using a metallic exhaust duct and compared its weight, cost, manufacturing processes, and ballistic performance to an exhaust duct designed with oxide-oxide ceramic matrix composites (CMCs).
Sisk-Kelley, Jessica, Misciagna, David, Glembocki, Edward, Nevinsky, Michael
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.
Plasma Surface Activation for Stronger, More Durable CFRP Bonds in AerospaceTBMG-546092/1/2026
Next Generation Carbon Fiber Composites 3D Printer for Hypersonic ResearchTBMG-546022/1/2026
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.
TVF 2026 - Foundations of Vertical Flight : Smart Scaling: Resilient Advanced Composite Supply Chains for Sustainable High-Rate Manufacturing Growth by TORAYSM_EVTOL_2026-52371/27/2026
Smart Scaling: Resilient Advanced Composite Supply Chains for Sustainable High-Rate Manufacturing Growth by TORAY
Wynn, Mat
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 mechanisms were investigated using white-light interferometry (WLI), scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS). Wear volumes were obtained from contact profilometry. Results show that PTFE addition reduced mechanical strength decreasing by 7.9%, 8.5% and 14.8% for 2%, 5% and 15% PTFE, respectively. In contrast, tribological performance improved, with COF stabilizing between 0.03-0.08 and wear rate decreasing from 5.6 × 10-4 mm3/N.m (no lubricant) to 1.0 × 10-4 mm3/N.m for 2 and 5% PTFE. At 15% PTFE, wear rate and COP increased to 2.3 × 10-4 mm3/N.m and 0.08, respectively. EDS analysis detected fluorine on the wear surfaces, confirming the formation of PTFE-rich tribolayers. However, excessive PTFE compromises mechanical integrity due to the formation of large reservoirs, leading to increased deformation and wear under high pressure. Thus, optimal performance results from balancing PTFE content and mechanical in robustness.
Hromatka, Matheus, Salvaro, Diego B., Binder, Cristiano, Michelotti, Alvaro C., Berto, Lucas F.
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 performance of these composites with metals used in the automotive industry. Considering aspects such as mechanical properties, thermal properties, corrosion resistance, collision behavior, weight, economic and sustainable impact, and social impact, hybrid composites presented greater advantages for applications than metal alloys. A finite element analysis (FEA) is conducted to assess the viability of composites, evaluating key mechanical parameters under realistic loading conditions. The methodology of the computational simulation quantitatively evaluates the structural behavior of the new hybrid composites that can be used for applications in vehicles and the automotive industry. The environmental impact and economic viability of replacing metals with natural fiber-reinforced composites are also discussed, highlighting the advantages in terms of sustainability and energy efficiency. Finally, the technical challenges and future perspectives for implementing these composite materials are presented, analyzing the optimization and performance to facilitate large-scale production in the automotive sector.
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 processes introduce defects such as fiber waviness, breakage, and “eye-shaped” resin-rich zones, leading to varying degrees of reduction in in-plane tensile, compressive, and shear properties. Key parameters, such as Z-pin diameter/density/insertion angle, stitch thread diameter/density/pattern, decisively influence the performance enhancement and trade-offs. At the application level, Z-pin technology is mature, suitable for localized toughening of prepreg laminates and joint reinforcement, and is easily integrated into existing processes. Stitching technology, combined with automation and resin infusion processes, demonstrates unique advantages in manufacturing large-scale integrated structures, significantly enhancing damage tolerance. Despite their significant potential, the application of through-the-thickness reinforcement technologies in primary aircraft load-bearing structures remains limited. Their long- term performance under hygrothermal environments and fatigue endurance require further validation. Future efforts should focus on optimizing parameters to balance performance trade-offs and exploring new directions such as integrating health monitoring.
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% in urban conditions (12.4% higher than that of a single-motor solution); the design of an innovative mechanical system based on fractal theory to mimic an electric vehicle, which can support the development of high energy-efficiency electric vehicles.); the bionic thermal management flow channel based on fractal theory reduces the maximum temperature difference of the battery pack from 8.2°C to 3.1°C, and the pump power loss is reduced by 19%. The results provide a paradigm of engineering practice and theoretical innovation for the optimisation of mechanical systems in next-generation electric vehicles.
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 (Historical)12/15/2025
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, electrolyte circulation, and gas film formation) faced and future research directions to increase the process capabilities based on published research in the UA-ECDM process.
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
Composite Materials Handbook Volume 3 - Revision HR-64010/16/2025
The third volume of this six-volume compendium provides methodologies and lessons learned for the design, analysis, manufacture, and field support of fiber-reinforced, polymeric-matrix composite structures. It also provides guidance on material and process specifications and procedures for using the data that is presented in Volume 2. The information provided is consistent with the guidance provided in Volume 1, and is an extensive compilation of the current knowledge and experiences of engineers and scientists from industry, government, and academia who are active in composites. The Composite Materials Handbook, referred to by industry groups as CMH-17, is a six-volume engineering reference tool that contains over 1,000 records of the latest test data for polymer matrix, metal matrix, ceramic matrix, and structural sandwich composites. CMH-17 provides information and guidance necessary to design and fabricate end items from composite materials. It includes properties of composite materials that meet specific data requirements as well as guidelines for design, analysis, material selection, manufacturing, quality control, and repair. The primary purpose of the handbook is to standardize engineering methodologies related to testing, data reduction, and reporting of property data for current and emerging composite materials. It is used by engineers worldwide in designing and fabricating products made from composite materials.
CMH-17
Effect of Zirconia and Quarry Dust Reinforcements on Mechanical Properties of Al7079 Composite05-19-01-00086/29/2025
In this work, the microstructure and mechanical behavior of AL7079 metal matrix composites (MMCs) mixed with zirconia and quarry dusts are analyzed. The high-strength Al7079 can be further improved by the addition of zirconia particulates and quarry dust particles, a cost-effective reinforcement. Composite samples with different weight fractions of zirconia (2%, 4%, and 6%) and quarry dust (2%) were produced via a stir-casting technique. Scanning electron microscope (SEM) was engaged to examine the microstructure of the composites, which showed that the reinforcements were well integrated and bonded perfectly to the matrix material. A simple mechanical test of hardness, tensile, and impact strength revealed enrichment in hardness and tensile strength in comparison to the Al7079 alone, whereas the impact strength decreased. Composite containing 6% zirconia and 2% quarry dust improved both the hardness (95 BHN) and tensile strength (186 MPa) by 7%, outperforming the remaining composition thus an effective novel material for automotive sector.
Madan Kumar, K.N., Sathyanarayana, G.M., Kuldeep, B., Manu, S.S., Manjunath Yadav, S., Anand, H.R.
Automated Fiber Placement: Status, Challenges, and EvolutionR-5116/11/2025
Discover the cutting-edge technology driving the next generation of aerospace, automotive, and space exploration. Automated Fiber Placement: Status, Challenges, and Evolution offers a comprehensive dive into AFP—an innovative method that’s transforming how complex, lightweight structures are built. Over the last 50 years, fiber-reinforced composites have revolutionized industries, particularly aerospace, with carbon fiber reinforced polymers at the forefront. AFP has enabled lighter, more durable aircraft with reduced fuel consumption and improved longevity. As the aerospace industry advances with new platforms like the Boeing 787 and Airbus A350, AFP continues to evolve, integrating machine learning and automation to deliver higher efficiency and lower costs. This book serves as an essential guide, presenting a decade of research in clear, accessible language. Whether you're a student, engineer, or industry professional, you'll gain a thorough understanding of AFP and its transformative potential. Learn how it supports the rise of advanced air mobility and sustainable structures for commercial and defense aircraft, space habitats, and beyond. Join us on the journey to the future of composite materials and manufacturing, where AFP stands as the key to unlocking new possibilities for a more sustainable, efficient, and innovative world.
Harik, Ramy, Brasington, Alex
Carbon Fiber-Carbon Nanotube Yarn Hybrid ReinforcementTBMG-532336/1/2025
Innovators at the NASA Glenn Research Center have developed a toughened hybrid reinforcement material made from carbon fiber and carbon nanotube (CNT) yarn for use in polymer matrix composites (PMCs). The new material improves toughness and damping properties of PMCs, enhancing impact resistance, fatigue life, as well as structural longevity.
Light Weight Aluminum Composite Bearing Liners for Vertical LiftF-0081-2025-02405/20/2025
Gamma Alloys manufactures aluminum matrix composite bearing liners for helicopter transmissions that have the performance of steel liners at one third the weight. These bearing liners have diameters between 2.5 and 24 inches. Our composites are made by blending aluminum powders with spheroidized alumina particles. These powders are then vacuum hot pressed into billets. These billets are then extruded into shapes that can be machined into bearing liners. The extrusion process transforms the powder metallurgy product into a wrought product. Over 2000 liners have been made and are currently flying in R&D vehicles since 2018 with no maintenance issues.
Harrigan, William, Peabody, Micah, Zhang, Yuzheng
A Novel Operational Analysis Tool for Advanced Air MobilityF-0081-2025-02595/20/2025
The emerging Advanced Air Mobility (AAM) market is an increasingly important area of research and development within vertical lift. AAM operations will be characterized by short- to mid-range flight that will include urban and suburban corridors and high utilization business models such as on-demand ride-share and package delivery operations. AAM operations also have an enhanced need for durability of vehicle components with respect to impact and fatigue within unsteady environments such as urban canyons. Further business model constraints include the minimization of scheduled maintenance, while maintaining safety levels. A university leadership initiative (ULI), Innovative Manufacturing, Operation, and Certification of Advanced Structures for Civil Vertical Lift Vehicles (IMOCAS), combined research and software development to address these operational aspects. Another major focus of the ULI was the development of processes to integrate new advanced composite materials into AAM designs. These new composites, such as thermosets and thermoplastics, offer equal or enhanced performance at lower weights than traditional aviation materials. This paper provides an overview of the outcomes of the ULI, introducing new software, processes, and data available to the community for the AAM market, crosscutting large passenger operations and smaller medical or commercial cargo operations.
Smith, Marilyn, Bayoumi, Abdel, Corman, Jason, De Backer, Wout, Garcia, Elena, German, Brian, Matthews, Rhea, Payan, Alexia, Ziehl, Paul
Formability Comparison of Continuous and Stretch Broken Prepreg LaminatesF-0081-2025-04075/20/2025
The demand for carbon fiber reinforced polymers (CFRPs) is growing, especially for use in high-performance applications. Components manufactured of CFRP are made by layering sheets of carbon fibers within a resin matrix. Due to the fibers’ brittle nature, CFRPs are difficult to shape into complex forms, limiting adoption of the material in applications such as vertical lift systems. To address this limitation, researchers at Montana State University, Bozeman (MSU) are developing a new form of carbon fiber called stretch broken carbon fiber (SBCF). SBCF maintains the strength of continuous carbon fibers, while allowing for fiber slip that is used to create a pseudo-plastic strain response needed in most forming processes. Dome and bulge tests were used for comparing the formability response of IM7 MSU SBCF/977-3 with continuous Hexcel IM7 12K/977-3. Results showed increased formability of the MSU SBCF ones due to their ability to stretch under an applied load.
Shchemelinin, Yoni, Nelson, Jared, Ryan, Cecily, Bajwa, Dilpreet, Cairns, Douglas, Ridgard, Christopher, Amendola, Roberta
Advancing Helicopter Repair: Gamma's Innovative Materials for the U.S. ArmyF-0081-2025-03475/20/2025
Maintaining the operational readiness of military helicopters demands repair solutions that are fast, reliable, and adaptable. This paper presents the integration of Gamma Alloys' advanced metal matrix composites (MMCs) into additive manufacturing (AM) techniques - specifically Cold Spray and Friction Stir Additive Manufacturing (FSAM) - as a transformative approach to helicopter repair and replace for the US Army.
Peabody, Micah, Harrigan, William
Influence of Strain Rate Effect on Mechanical and Crashworthiness Properties of CFRP Composite Structures05-19-01-00025/6/2025
Composite materials are increasingly utilized in industries such as automotive and aerospace due to their lightweight nature and high strength-to-weight ratio. Understanding how strain rate affects the mechanical and crashworthiness properties of CFRP composites is essential for accurate impact simulations and improved safety performance. This study examines the strain rate sensitivity of CFRP composites through mechanical testing and finite element analysis (FEA). Experimental results confirm that compressive strength increases by 100%–200% under dynamic loading, while stiffness decreases by up to 22% at a strain rate of 50 s−1, consistent with trends observed in previous studies. A sled test simulation using LS-Dyna demonstrated that the CFRP crash box sustained an average strain rate of 46.5 s−1, aligning with realistic impact conditions. Incorporating strain rate–dependent material properties into the FEA model significantly improved correlation with experimental crashworthiness data, reducing discrepancies in peak acceleration, mean acceleration, and displacement by 6.5%, 5.9%, and 6.3%, respectively. These findings reinforce the necessity of accounting for strain rate effects in crash simulations and composite structure design, ensuring more accurate predictions of impact performance and structural integrity in safety-critical applications.
Badri, Hesam, Jayasree, Nithin Amirth, Loukodimou, Vasiliki, Omairey, Sadik, Bradbury, Aidan, Lidgett, Mark, Page, Chris, Kazilas, Mihalis
Additive Manufacturing in the Mobility Industry: Vol. 4EPRCOMPV0120244/30/2025
Phillips, Paul, Slattery, Kevin, Coyne, Jennifer, Hayes, Michael
Material-Combined Vehicle Brake Disc Design for Enhanced Cooling Performance2025-01-81894/1/2025
The improvement of heat dissipation performance of ventilated brake discs is vital to braking safety. Usually, the technical approaches shall be material optimization or structural improvement. In this paper, a simulation model of the heat transfer of brake discs is established using STAR-CCM+ software. Cast iron, aluminum metal matrix composite (Al-MMC), and carbon-ceramic composite materials (C-SiC) are compared. The results show that: Al-MMC has better thermal conductivity so that a more uniform temperature gradient distribution shall be formed; C-SiC has poorer heat capacity yet, according to previous studies, it has better thermal stability, which is the ability to ensure its friction factor under high-temperature condition; cast iron performs better with convective heat transfer rate, which enhances the heat transfer between the surface and surrounding flow field. Based on the results, this paper proposes four types of material combined brake discs using different friction materials and geometry structures. Al-MMC and C-SiC friction layers are compared at the level of material application. At the level of geometric structure, 3mm and 5mm are chosen to be the thickness, and the different simulations of simulation are discussed. For material selection, the material-combined discs have lower friction surface temperatures compared to the use of single materials, and the overall temperature gradient distribution is more uniform; for the selection of the friction layer thickness, the use of the 3mm composite friction layer scheme, regardless of the Al-MMC or C-SiC, has a lower friction surface temperature than the 5mm friction layer scheme. For different friction layer thicknesses, using a 3mm friction layer has a lower friction surface temperature than 5mm regardless of the materials, and the temperature distribution is more uniform. However, due to the increased cast iron content, the 3mm solution is less lightweight than the 5mm solution. Overall, the material combination approaches can offer a significant performance improvement over the single material discs, which contributes to the safety of automotive braking.
Wang, Jiarui, Jia, Qing, Zhao, Wentao, Xia, Chao, Yang, Zhigang
Computational Evaluations of Structural Integrity in Unmanned Aquatic Vehicles Utilizing Various Conventional and Hybrid Composites Using Hydro-Structural Analyses2025-28-00562/7/2025
This study focuses on developing and deploying an Unmanned Aquatic Vehicle (UAV) capable of underwater travel. The primary objectives of this project are to detect the presence of dimethyl sulfide and toluene, as well as to identify any potential oil leakage in underwater pipelines. The UAV has a maximum operating depth of 300 m below the water surface. The design of this UAV is derived from the natural design of Rhinaancylostoma, an underwater kind of fish. The maximum operational setting for this mission is fixed at a depth of approximately 300 m beneath the surface of the sea, and the choice of this species is suitable for fulfilling the objectives of this undertaking. This technology will mitigate the risk associated with human interaction in inspection processes and has the potential to encompass various other resources in the future. The initial design data of the UAV is determined using analytical processes and verified formulas. The selection of the airfoil is done by comparing numerous options, such as NACA 0006, NACA 0020, and NACA 0024. The comparison investigation shows that the NACA 0008 has a lower coefficient of drag. ANSYS Workbench tool is utilized for executing computational analysis, encompassing hydrodynamic and hydro-structural simulations. An innovative computational molding technique is utilized as a preprocessing step. Structural examination is conducted in a two-step procedure, utilizing eight different materials. The selected materials for analysis are Boron fiber reinforced polymer (BFRP), AS-Carbon fiber reinforced polymer (CFRP), T-300-CFRP, HMS-CFRP, GY-70-CFRP, Kevlar fiber reinforced polymer, E-Glass fiber reinforced polymer (GFRP), and S-GFRP. The solid model of the UAV is subjected to computational analysis under two distinct loading circumstances. This analysis helps in identifying the most effective materials for future examination of the structure utilizing layer model molding in ANSYS ACP software. Afterwards, hybrid composites are prepared with the imposition of advanced fibers, and so the hydro-structural analyses are computed. The hydrodynamic parameters are calculated, and as a result, the structural performance of UAV is monitored. In the end, the most optimal material is chosen for the developed hydrodynamically efficient UAV's construction, to carry out the application efficiently and reliably.
Veeraperumal Senthil Nathan, Janani Priyadharshini, Rajendran, Mahendran, Arumugam, Manikandan, Raji, Arul Prakash, Sakthivel, Pradesh, Madasamy, Senthil Kumar, Stanislaus Arputharaj, Beena, L, Natrayan, Raja, Vijayanandh
Thermal Buckling Analysis of Axially Layered Aluminium Zirconia Functionally Graded Beam2025-28-01202/7/2025
This study investigates the thermal buckling behavior of axially layered functionally graded material (FGM) thin beams with potential applications in automotive structures. The FGM beam is constructed from four axially stratified sections, with the proportional amount of metal and ceramic fluctuating through the thickness. The buckling analysis is carried out for three different support configurations: clamped-clamped, simply supported-simply supported, and clamped-simply supported. The primary objective is to identify the optimal thermal buckling temperature of the FGM thin beam using the Taguchi optimization method. Beam arrangements are established using a Taguchi L9 orthogonal array and analyzed using finite element software (ANSYS). Layers 1-4 of the axially layered beam are considered process parameters, while the thermal buckling temperature is the response parameter. Minitab software performs an Analysis of Variance (ANOVA) with a 95% confidence level to identify the most influential layer and its relative contribution to the buckling temperature. The results, confirmed by a separate test, indicate that Layer 2 substantially affects the critical buckling temperature within the beam. Ultimately, the optimal critical buckling temperature is forecasted based on the 95% confidence interval of the confirmation analysis and population data. This research provides valuable insights into optimizing the thermal performance of FGM thin beams for automotive applications, where lightweight structures with high thermal stability are crucial. Engine Hood A non-uniformly heated engine hood can buckle and warp, affecting aesthetics and potentially causing fitment issues with fenders or compromising safety features like hood latches. The findings can guide the design and development of vehicle heat-resistant components, potentially leading to improved fuel efficiency and safety.
Pawale, Deepak, Bhaskara Rao, Lokavarapu
Optimization of Machining Parameters Based on Desirability Function Analysis for Stir Casted Aluminium Hybrid Metal Matrix Composites2025-28-01192/7/2025
These days, aluminum and other material composites are indispensable for a wide range of engineering applications, including automotive-related ones. The machinability investigations of hybrid metal matrix composites (HMMC) made of Al 6061 are reported in this paper. Graphene nanoparticles (GNp) and boron carbide were used to reinforce Al6061 alloy for the experiment. Stir casting was used to create the hybrid composite under the right circumstances. Since HMMC is not easy to machine using conventional machining procedures, the advanced method of electrical discharge machining (EDM) was used. EDM machinability studies were carried out on stir-casted Al-B4C-GNP composite materials to examine the effects of wire EDM machining variables, including current, pulse on, and pulse off, on surface roughness and material removal rate. Taguchi based Desirability function Analysis was used to optimize the EDM process parameters for maximization of the material removal rate (MRR) and minimization of the surface roughness responses. The desirability function analysis yielded the composite desirability value, which was used to estimate the ideal machining parameters. Analysis of variance (ANOVA) was also used to determine the components that contributed significantly.
Kala, Lakshmi K, Madhuri, K, Reddy, Damodara, Tarigonda, Hariprasad, R L, Krupakaran, Tharehallimata, Gurubasavaraju, Naidu, B Vishnu Vardhana
Thermal Buckling Analysis of Axially Layered Aluminium Silicon Nitride Functionally Graded Thin Beam using Taguchi Method2025-28-01722/7/2025
This research examines the thermal instability of slender beams composed of functionally graded materials (FGMs), with a specific focus on their suitability for engine hood components. The FGM combines the durability of aluminum with the heat tolerance of silicon nitride. The study aims to determine the maximum temperature the beam can withstand without buckling under various support conditions, simulating the uneven heat distribution experienced by engine hoods in actual use. The FGM structure comprises four longitudinally arranged layers, where the ceramic and metallic components gradually shift across the thickness. Finite element modeling software (ANSYS) is utilized to examine the buckling response under diverse temperature conditions. To enhance the thermal performance of the engine hood panel, the Taguchi L9 orthogonal array methodology is employed utilizing Minitab 19 software. The first four layers of the FGM beam are defined as process variables, while the critical buckling temperature is designated as the output variable. The material composition of each layer is adjusted across three levels to assess its impact on the hood panel's resistance to thermal strain. The Signal-to-Noise (S/N) ratio is employed to determine the ideal configuration for achieving the highest possible critical buckling temperature. This investigation also uncovers the influence of ceramic and metallic composition on the behavior of each layer, enabling the creation of an FGM hood panel that offers superior heat resistance and structural robustness. Additionally, an Analysis of Variance (ANOVA) is performed with a 95% confidence interval to identify the layer with the most substantial impact on the critical buckling temperature and quantify its relative influence. This information is essential for customizing the FGM composition to target areas of the hood panel exposed to the highest thermal loads, like the region directly above the engine. Finally, utilizing the 95% confidence interval derived from the confirmatory analysis and population statistics, the ideal maximum temperature before buckling for the FGM engine hood component is projected. This investigation yields significant knowledge for the development of lightweight, thermally resilient FGM engine hood structures. By refining the material composition of each layer, designers can produce engine hoods with superior resistance to heat-induced warping, potentially resulting in improved vehicle safety and functionality.
Pawale, Deepak, Bhaskara Rao, Lokavarapu
Enhancing Disc Brake Performance: Investigating Squeal Noise, Wear, and the Application of Functionally Graded Materials in Brake Rotors2025-28-01622/7/2025
Disc brakes play a vital role in automotive braking systems, offering a dependable and effective means of decelerating or halting a vehicle. The disc brake assembly functions by converting the vehicle's kinetic energy into thermal energy through friction. The performances of the brake assembly and user experience are significantly impacted by squeal noise and wear behaviour. This paper delves into the fundamental mechanisms behind squeal noise and assesses the wear performance of the disc brake assembly. Functionally graded materials (FGMs) are an innovative type of composite material, characterized by gradual variations in composition and structure throughout their volume, leading to changes in properties such as mechanical strength, thermal conductivity, and corrosion resistance. FGMs have emerged as a groundbreaking solution in the design and manufacturing of brake rotors, addressing significant challenges related to thermal stress, wear resistance, and overall performance. These studies evaluate the noise and wear behaviour of disc brake assemblies made with FGMs. The paper also investigates the application of FGMs in brake rotors, highlighting their distinctive properties and the advantages they offer to automotive braking systems. The study underscores the importance of further research and development to fully leverage the benefits of FGMs in enhancing brake system performance.
C V, Prasshanth, S, Gurumoorthy, Bhaskara Rao, Lokavarapu, S, Sridhar, S, Badri Narayanan, Kumar, Ajay, Biswas, Sayan
Forced Vibration Analysis of Cracked Functionally Graded Beams2025-28-01692/7/2025
This study investigates the forced vibration characteristics of a functionally graded material (FGM) beam possessing a square cross-section and featuring a V-shaped crack. The FGM beam exhibits a gradual transition in mechanical composition from a ceramic to a metallic surface. Employing finite element analysis software, a comprehensive numerical analysis is conducted to evaluate the frequencies and mode shapes of the cracked FGM beam under simply supported boundary conditions. The study meticulously explores the effects of various crack parameters, including crack opening width, depth, and location. The findings highlight the significant influence of the crack opening width on the frequencies, indicating that wider cracks result in decreased frequencies across all mode shapes. Conversely, the impact of crack depth and location on the dynamic behavior of the cracked FGM beam within the studied ranges appears relatively minor. These insights offer valuable perspectives into the vibrational characteristics of cracked FGM beams, which can contribute to structural health monitoring and allow optimizing their design. In automotive applications, these insights aid in the development of more resilient vehicle components and improving the overall durability and reliability of automotive structures.
D, Manish, C V, Prasshanth, N, Suhas, Bhaskara Rao, Lokavarapu
Innovative Design and Multi-Parametric Computational Investigations on the Propulsive System of a Pentacopter Unmanned Aerial Vehicle2025-28-01812/7/2025
This work focuses on the design and multi-parametric analysis of a designed propeller for a Pentacopter unmanned aerial vehicle (UAV). The basic and secondary design inputs, along with performance data like propeller diameter, pitch angle, chord length, and lift coefficient, are established using a standard analytical method. Approximately ten distinct airfoils, specifically NACA 2412, NACA 4109, NACA 4312, NACA 4409, NACA 4415, NACA 5317, NACA 6409, NACA 6412, NACA 23024, and NACA 25012, are evaluated over 13 Reynolds Numbers with the angle of attacks (AOA) of 20, varying from -5 to 15 degrees, for the purpose of detailed propeller design. The lift and drag coefficient values for ten distinct airfoils, utilizing a Reynolds number of 13 and 20 angles of attack, are obtained from the XFOIL software. Three sophisticated airfoils are selected from a pool of ten based on their high Lift-to-Drag (L/D) ratio performance. The selected airfoils with a high L/D ratio are NACA 6409, NACA 4109, and NACA 4312. The shortlisted three airfoil-based propellers are designed using a sophisticated modelling tool, i.e., 3D EXPERIENCE. The fourth modelled propeller is designated as the Hybrid propeller, which integrates three airfoils and three propellers, utilizing just NACA 6409, NACA 4109, and NACA 4312 airfoils, respectively. In ANSYS R2 2023 software, the four propellers are examined using a single moving reference frame approach, which facilitates an efficient simulation for the rotating frame in computational fluid dynamics by establishing appropriate boundary conditions. The analysis is conducted using fluid-structure interaction simulations involving carbon fiber reinforced polymer (CFRP), Boron fiber reinforced polymer (BFRP), Kevlar fiber reinforced polymer (KFRP) and glass fiber reinforced polymer (GFRP) materials. Eight distinct materials are evaluated, including BFRP, HMS-CFRP, AS-CFRP, S-GFRP, E-GFRP, GY-70-CFRP, K-49-UD-FRP, and T-300-CFRP. The Hybrid propeller emerges as the optimal performer, particularly when combined with GY-70-CFRP, in terms of minimized total deformation under high loads. The selected propeller is distinguished by reduced torque, which correlates with diminished power consumption during operation, whereas all other propellers display comparable performance metrics concerning the applications relevant to the Pentacopter UAV.
Veeraperumal Senthil Nathan, Janani Priyadharshini, Arumugam, Manikandan, Rajendran, Mahendran, Solaiappan, Senthil Kumar, Kulandaiyappan, Naveen Kumar, Madasamy, Senthil Kumar, Stanislaus Arputharaj, Beena, L, Natrayan, Raja, Vijayanandh
Material Augmentation for Coaxial Propellers of Titan’s Unmanned Airship: Implementation of Advanced Composites for the Propulsive System under Unconventional Loading Conditions with Incorporation of Structural Integrity Examinations2025-28-01672/7/2025
Exploration vehicles on Titan are to be developed with considerations on the atmosphere present, especially the abundance of Nitrogen. This study focuses on identification of optimum materials for the propellers supporting an airship specifically created for Titan exploration. The base airship is designed to accommodate the coaxial propeller. The base of this airship is to be developed with four weather stations for collection of data samples. The stations are installed on inflatable platforms and have storage devices for recording and transmitting data collected by the aerobot. The airship will operate in Titan's atmosphere and atmospheric conditions, focusing on its design and computational analysis of structural effects and fluid dynamics. The Titan aerobot is built with a co-axial 4-blade propeller, horizontal and vertical fins, and a reaction wheel for yaw maneuvers. The co-axial propulsive system is capable of overcoming drag during steady level flight in the Titan atmosphere. Structural parameter research is conducted during the material selection process for the propeller, examining materials from common materials to isotropic and orthotropic composites, metal alloys, and various composites. Two-way coupling fluid structural interaction is the foundation of computational structural analysis, transferring loads from transient flow analysis to the structure. The best performing materials for each scenario are determined based on the combined results for gust loads. By importing the aerodynamic load created from the gust effects, the structural integrity incorporated with material data is determined on the basis of Equivalent stress, strain, strain energy and deformation. From the analysis conducted, it is inferred that the material GY-70 fiber-based composite, belonging to Carbon fiber category, is seen to be providing the most favorable results with comparatively less deformation, hence providing optimum materials for the unconventional conditions provided.
Baskar, Sundhar, Vinayagam, Gopinath, Pisharam, Akhila Ajith, Gnanasekaran, Raj Kumar, Raji, Arul Prakash, Stanislaus Arputharaj, Beena, L, Natrayan, Ganesan, Balaji, Raja, Vijayanandh
Nanostitches for Lighter, Tougher Composite MaterialsTBMG-524632/1/2025
To save on fuel and reduce aircraft emissions, engineers are looking to build lighter, stronger airplanes out of advanced composites. These engineered materials are made from high-performance fibers that are embedded in polymer sheets. The sheets can be stacked and pressed into one multilayered material and made into extremely lightweight and durable structures.
Fabrication and Characterization of Silicon Carbide and Aluminum Oxide Reinforced 6061-T6 Aluminum Matrix Composites2024-01-52621/28/2025
Aluminum Matrix Composites (AMCs) are gaining traction in aerospace, automotive, and marine industries due to their superior mechanical properties. By integrating hard ceramic particles such as silicon carbide (SiC) and aluminum oxide (Al₂O₃) into aluminum matrices, these composites exhibit enhanced wear resistance and strength-to-weight ratios. This study explores the fabrication and characterization of 6061-T6 aluminum alloy matrix composites, reinforced individually with SiC and Al₂O₃ particles through the squeeze casting technique. The research includes a comprehensive analysis of microstructures and mechanical properties, focusing on compressive strength, Brinell hardness, and tribological behavior. Findings reveal that SiC and Al₂O₃ reinforcements boost compressive strength by up to 27% and 47%, respectively, and increase hardness by up to 29% and 20%, respectively, compared to unreinforced aluminum.
Thirumavalavan, R., Santhosh, V., Sugunarani, S., Regupathi, S., Sundaravignesh, S.
Wear Characteristics of Hybrid Aluminium 8011 Matrix Composites Reinforced with Silicon Carbide Particles and Titanium Diboride2024-01-52591/28/2025
This study investigates the wear and hardness properties of AA8011 hybrid metal matrix composites (MMCs) reinforced with silicon carbide (SiCp) and titanium diboride (TiB₂), addressing a significant gap in the existing literature regarding the optimization of reinforcement levels in AA8011. The goal is to enhance the material’s wear resistance and hardness for high-performance applications. While AA8011 is known for its excellent mechanical properties and corrosion resistance, limited research has focused on optimizing both wear behavior and surface hardness through the combination of TiB₂ and SiCp reinforcements. Using the pin-on-disk method, this study explores various compositions, showing that the composite containing 2% TiB₂ and 1% SiCp exhibited the best wear resistance, with a 25% improvement over the base alloy, and an increase in hardness by more than 115%. Developing AA8011-based composites with enhanced durability and hardness for use in demanding environments such as automotive and aerospace applications.
Thirumavalavan, R., Mugendiran, V., Santhosh, V., Manoj, M., Sundaravignesh, S.
Synthesis and Machining Characteristics Evaluation of Silicon Nitride Made Magnesium Alloy Composites05-18-03-00171/20/2025
The advantages of magnesium alloy composites over traditional engineering materials include their high strength and lightweight for automotive applications. The proposed work is to compose the AZ61 alloy composite configured with 0–12% silicon nitride (Si3N4) via semisolid-state stir processing assisted with a (sulfur hexafluoride—SF6) inert environment. The prepared AZ61 alloy and AZ61/4% Si3N4, AZ61/8% Si3N4, and AZ61/12% Si3N4 are machined by electrical discharge machining (EDM) under varied source parameters such as pulse On/Off (Ton/Toff) time (100–115/30–45 μs), and composition of composite. The impact of EDM source parameters on metal removal rate (MRR) and surface roughness (Ra) is measured. For finding the optimum source for higher MRR and good surface quality of EDM surface, the ANOVA optimization tool with L16 design is executed and analyzed via a general linear model approach. With the influence of ANOVA, the Ton/Toff and composite composition found 95.42%/1.27% and 0.36% impact for MRR and 30.74%/21.01%/18.27% of Ton, Toff, and Ra. The optimum parameters for electrical discharge machining have been determined, and the composite material of AZ61/8% Si3N4 has been identified as having a favorable MRR/Ra value compared to other materials.
Venkatesh, R.
Effect of TiO 2 & B 4 C on the Mechanical Behavior and Microstructural Properties of Light Weight Hybrid Metal Matrix Composites for Compact Automobile Applications2024-01-520812/10/2024
This Experimental study demonstrates the influence of titanium dioxide (TiO2) and boron carbide (B4C) reinforcements on the mechanical behaviour and microstructural characteristics of lightweight hybrid metal matrix composites (HMMCs) tailored for compact automobile applications. The Aluminium metal matrix composites were synthesized using stir casting technique to ensure uniform dispersion of titanium dioxide (TiO2) and boron carbide (B4C) reinforcements within the aluminium matrix. Characterization techniques such as scanning electron microscopy (SEM) and optical Microscopy, were employed to analyze the microstructural evolution and phase distribution. Mechanical properties such as hardness, tensile strength, and wear resistance were systematically evaluated. The results demonstrated significant enhancements in mechanical performance with 38% increase in tensile strength, 22% increase in impact strength which are attributed to the synergistic effects of TiO2 and B4C. These improvements were correlated with refined grain structures and the formation of stable intermetallic compounds. The optimized HMMCs exhibited a remarkable balance of low density and high strength, making them highly suitable for automotive components requiring weight reduction without any compromise in durability and performance. This research provides valuable insights into the development of high-performance, lightweight materials for the automotive industry.
Jaswin, M. Arockia, Geetha, R., Mathialagan, Saravanan, Suresh, S.
Corrosion Properties of Aluminium 7075 Basalt Particulate Reinforced Metal Matrix Composite Prepared by Stir Casting2024-01-520112/10/2024
Basalt-based products are known to provide substantial wear and corrosion resistance even in harsh environments. This paper aims to explore the stir casting technique as an efficient way to reinforce basalt particulates into Aluminium (AA7075). The properties such as hardness, ultimate tensile strength with corrosion behaviour of the composites were evaluated and compared with as-cast AA7075 fabricated under the same conditions. It is evident from the results that an increase in basalt particulate content significantly increases the ultimate tensile strength of 216 MPa and hardness of 123 VHN. The mechanism of bonding between basalt particulate and aluminum alloy at the interface was studied using scanning electron microscopy (SEM). AA7075 matrix composites exhibited better corrosion resistance and they showed enhancement in thermal and mechanical properties.
Vallimanalan, A., Murali, M., Mahendran, R., Manivannan, S.
Wear Behaviour of Banana Fiber Mat/Rice Husk/ Multi-Walled Carbon Nanotube Hybrid Polymer Matrix Composites Using Taguchi Technique2024-01-523312/10/2024
The main aim of this experimental study is to investigate the wear properties of a hybrid composite material composed of a banana fibre mat, rice husk powder, and an epoxy matrix polymer filled with multi-walled carbon nanotubes (MWCNT). This research emphasizes the assessment of the composite's characteristics and behaviour. The adjustment of various ratios of fibres and fillers within polymer matrix hybrid composites finds application in numerous engineering fields, particularly in the automotive and aerospace industries. The experimental evaluation is conducted using a pin-on-disk wear tester to analyze the specimens in terms of pin wear, friction coefficient, and friction force. Experimental trials were conducted using L9 orthogonal arrays following the Taguchi design of experiments, and the output response was optimized by implementing a hybrid approach of Gray relational analysis. It depends upon the suitability of the wear performance needs of the application to obtain the optimal range of use and study of ANOVA software. The ideal conditions have been attained to minimize wear, coefficient of friction, and friction force. After the testing, the specimen's scanning electron/optical microscope images illustrate the wear and primary wear mechanisms. Confirmed experiments with optimal conditions show that the results are closer to the expected results.
Senthilkumar, N., Ramu, S., Yuvaperiyasamy, M., Sabari, K.
Analyzing the Effect of Silicon Carbide and Flyash Reinforcement on the Phase Morphology and Mechanical Properties of 7075 Aluminum Alloy Produced through Stir-Casting Process2024-28-016512/5/2024
Growing demand for fuel-efficient vehicles and lower CO2 emissions has led to the development of lightweight materials. Aluminum composites are being used to achieve lightweighting to improve performance, efficiency, and sustainability across various industries. The unique properties of aluminum composites make them an attractive choice for researchers and designers looking to optimize their products. Reinforcement materials play a vital role in the development of these composites, acting as barriers to dislocation movement within the aluminum matrix. This effectively strengthens the material and prevents deformation under load, resulting in increased tensile strength and fatigue resistance. Additionally, aluminum composites exhibit improved thermal and electrical conductivity, making them suitable for automotive applications. In this study, metal matrix composites (MMCs) of aluminum 7075 alloys were developed using silicon carbide (SiC) and flyash as reinforcements. Three different compositions were cast using the stir casting technique: 10% fly ash, 10% SiC, and 5% SiC plus 5% fly ash. A detailed characterization of these composites was conducted using Scanning electron microscopy coupled with Energy-Dispersive X-ray spectroscopy, focusing on the metallurgical characteristics of the materials. This analysis revealed the distribution of eutectic phases, primary aluminum matrix, intermetallic compounds, chemical zonation, and precipitates at grain boundaries, resulting in improved strength, hardness, and wear resistance. The results showed that the flyash composition exhibited increased wear resistance due to the formation of complex phases, while the SiC composition showed improvements in tensile strength and hardness.
Manwatkar, Asmita Ashok, Santosh Jambhale, Medha, Mahagaonkar, Nitin, Sharma, Dipesh
Evaluation of Mechanical Properties of Reduced Stress Localized Aluminium Composites for Automobile Applications2024-28-024112/5/2024
The modern-day development in the field of mobility demands the development of advanced engineering materials for various engineering applications. Composite materials play a pivotal role in the advancement of mobility by achieving overall weight reduction and thereby contributing to the sustainability of the environment. Metal matrix composites has played a crucial role over the last few decades in the automotive industry replacing the conventional metal in achieving a better strength to weight ratio. Metal matrix composites can be a combination of a metal and a ceramic combined at a macroscopic level to achieve better mechanical and tribological properties at a reduced weight to strength ratio. Aluminium being one of the largest metals widely used in automobiles, are gradually being replaced with Aluminium metal matrix composites. Aluminium – silicon carbide composite is a key interest among the researchers due to the attractive mechanical and tribological properties that enhance the performance of automobiles. The most common applications of aluminium silicon carbide composites in automobiles are pistons, cardan shaft, connecting rods etc. This study is focused on the chemical interfacial reaction between silicon carbide and aluminium matrix which occurs during the elevated temperature of casting process and thereby creating stress localization due to the formation of aluminium carbide in the matrix. The chemical reaction also results in the degradation of silicon carbide which can lead to poor performance of the composite. Hence it is very important to keep this chemical reaction to a minimum level. This research is centered on finding out an effective solution for hindering this chemical reaction by adding a material which is cheap, easily available and existing as an industrial waste material. Utilizing it for the composites can contribute to the sustainability of nature as well. Various mechanical properties are evaluated for this hybrid composites to evaluate the performances.
Valsan, Ashray
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