Browse Topic: Advanced composite materials

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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.
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
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.
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 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
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
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
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
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
ABSTRACT 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
Formability Comparison of Continuous and Stretch Broken Prepreg LaminatesF-0081-2025-04075/20/2025
ABSTRACT 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, Ryan, Cecily, Bajwa, Dilpreet, Cairns, Douglas, Ridgard, Christopher, Amendola, Roberta, Nelson, Jared
A Novel Operational Analysis Tool for Advanced Air MobilityF-0081-2025-02595/20/2025
ABSTRACT 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
Bayoumi, Abdel, De Backer, Wout, Matthews, Rhea, Ziehl, Paul, Smith, Marilyn, Corman, Jason, Garcia, Elena, German, Brian, Payan, Alexia
Advancing Helicopter Repair: Gamma's Innovative Materials for the U.S. ArmyF-0081-2025-03475/20/2025
ABSTRACT 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
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
Wang, Jiarui, Jia, Qing, Zhao, Wentao, Xia, Chao, Yang, Zhigang
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
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
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
Veeraperumal Senthil Nathan, Janani Priyadharshini, Rajendran, Mahendran, Arumugam, Manikandan, Raji, Arul Prakash, Sakthivel, Pradesh, 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
Baskar, Sundhar, Vinayagam, Gopinath, Pisharam, Akhila Ajith, Gnanasekaran, Raj Kumar, Raji, Arul Prakash, Stanislaus Arputharaj, Beena, L, Natrayan, Ganesan, Balaji, 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
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
Kala, Lakshmi K, Madhuri, K, Reddy, Damodara, Tarigonda, Hariprasad, R L, Krupakaran, Tharehallimata, Gurubasavaraju, Naidu, B Vishnu Vardhana
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
D, Manish, C V, Prasshanth, N, Suhas, Bhaskara Rao, Lokavarapu
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
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
C V, Prasshanth, S, Gurumoorthy, Bhaskara Rao, Lokavarapu, S, Sridhar, S, Badri Narayanan, Kumar, Ajay, Biswas, Sayan
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
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
Venkatesh, R.
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
Senthilkumar, N., Ramu, S., Yuvaperiyasamy, M., Sabari, K.
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
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.
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
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
Valsan, Ashray
‘First of Its Kind’ Composite Material to Help Space Vessels Travel Longer DistancesTBMG-5212612/1/2024
The future of space travel is seemingly changing by the day and a Coventry University academic is doing his bit to stay at the front of the space race.
Recent Developments on Aluminum 7075-Based Composite with Industrial Waste Fly Ash by Stir Casting and Their Applications05-18-02-000911/7/2024
Recent developments in manufacturing techniques and the development of Al7075 metal matrix composites (MMCs) with reinforcements derived from industrial waste have been steadily gaining popularity for aerospace and automobile applications due to their outstanding properties. However, there are still a lot of limitations with these composite materials. A great deal of research has been done to create new Al7075 MMC materials with the use of economic fly ash (FA) that possesses superior mechanical properties, corrosion resistance, density, and cycle cost. This review outlines different synthesis techniques used in the development of Al7075 MMCs using stir casting. Effects of FA along with other reinforcements on the mechanical, wear, machining, and microstructural properties of the composite are also discussed. Finally, a summary of the application of FA-based MMCs and a recap of the previous discoveries and challenges are reported. Future scope and potential areas of application are
Kumar, Randhir, Mondal, Sharifuddin
Static Analysis of Aluminum Alloy Ingot/Zirconium Diboride Composites for Automotive Applications05-18-01-000710/16/2024
The aim of this work is to develop a composite material and investigate its mechanical characteristics especially suited for automotive applications, and finite element analysis (FEA) of fabricated composite is carried out to examine the mechanical behavior of composites. Utilizing aluminum alloy ingot (LM13) as the matrix material and zirconium diboride (ZrB2) as reinforcement, this work creates composites with improved mechanical and physical properties by accounting impact, tensile, compression, and hardness behavior. FEA is used to examine the increasing behavior of material properties for various volume segments of reinforcement (2.5, 5, 7.5, and 10 wt%) that are supplied to the matrix to determine an acceptable volume percentage of composite based on their input features. In FEA, the impact, tensile, compression, and hardness characteristics of the composite model are investigated by considering von Mises stress, equivalent elastic strain, and total deformation. The experimental
Vijayan, S. N., Chelladurai, Samson Jerold Samuel, Saiyathibrahim, A., Infant Jegan Rakesh, A. J., Thriveni, K., Preethi, V., Jatti, Vijaykumar S., Karthik, S., Balaji, K., Saranya, S.
Synthesis and Characterization of AA6351/SiC Composites Using Ball Milling Combined with Hot Extrusion05-18-01-000310/3/2024
In this investigation, AA6351 alloy matrix composites with a larger volume proportion of SiC (20 wt%) were fabricated and tested for microstructure and mechanical behavior. Composites were hot extruded from mechanically milled matrix and reinforcements. Hot extrusion uniformly distributed reinforcements in the matrix and strengthened phase interaction. Mechanical ball milling causes AA6351 powder to become more homogeneous, reducing the mean particle size from 38.66 ± 2.31 μm to 23.57 ± 2.31 μm due to particle deformation. The micrograph shows that the SiC particles are equally dispersed in the AA6351 matrix, avoiding densification and reinforcing phase integration issues during hot extrusion. In hot extrusion, SiC particles are evenly distributed in the matrix, free of pores, and have strong metallurgical bonds, resulting in a homogenous composite microstructure. SiC powders and mechanical milling increase microhardness and compressive strength, giving MMC-A 54.9% greater than AA6351
Saiyathibrahim, A., Murali Krishnan, R., Jatti, Vinaykumar S., Jatti, Ashwini V., Jatti, Savita V., Praveenkumar, V., Balaji, K.
Product Design and Testing for Automotive Engineering Volume IIR-5509/17/2024
Explore Product Design and Testing for Automotive Engineering: Volume II, an essential guide reshaping vehicle manufacturing with unprecedented reliability. As part of SAE International's DOE for Product Reliability Growth series, this practical resource introduces cutting-edge methodologies crucial for predicting and improving product reliability in an era of automotive electrification. The book navigates statistical tolerance design, showcasing how variability in part fabrication and assembly can enhance reliability and sustainability. Key topics include: - Statistical tolerance design's impact on manufacturing and material selection, focusing on non-normal distributions' effects on product assembly and cost. Methods like maximum likelihood estimators and Monte Carlo simulations are used for assembly strategy synthesis. - Reliability DOEs using log-location-scale distributions to estimate lifetimes of non-normally distributed components, especially in accelerated life testing. It
Chiang, Young J.
Development of Aluminum-Based Metal Matrix Composite for Dry Bearings Reinforced with Titanium Dioxide and Silicon Carbide2024-01-50919/2/2024
Metal matrix composites (MMCs) have evoked a keen interest in recent times for their potential applications in automotive and aerospace industry components. One such particulars include dry sliding bearings, which have widespread applications in various industries due to their self-lubricating properties, high wear resistance, and low maintenance requirements. The wear as a consequence of metal-to-metal friction can have a detrimental effect, expediting malfunctions or much more adverse spin-offs on the whole system. This study focuses on the development and characterization of a novel dry bearing material composed of a MMC consisting of aluminum (Al), titanium dioxide (TiO2), and silicon carbide (SiC). Tribological tests revealed a low friction coefficient, ensuring efficient and reliable operation. The results indicate the enhancement of MMC’s performance and durability in dry bearings, contributing to the efficiency and reliability of engineering systems. The study not only
Ravi Raj, V., Dhivya Praban, S. V., Jayasooriya, M., Sairam, T. S.
Enhanced Mechanical Properties of Carbon Fiber/Epoxy Nanocomposites Modified with Amine-Functionalized Graphene05-17-04-00277/13/2024
Since the beginning of time, people have desired the best materials for production. Metals are often too heavy to be used in manufacturing. Polymer matrix composites (PMC) can be considered more dependable than metals in practical applications because of their high strength-to-weight ratio so it is a good alternative of metals. The article’s objective is to investigate the various PMC properties that are reinforced with carbon fiber. CFRP (Carbon fiber-reinforced polymer) was first made using the hand layup method with carbon fiber as a reinforcement and epoxy resin as a matrix after a thorough literature review. As CFRP have higher stiffness and superior “strength-to-weight ratio,” fiber-reinforced polymer (FRP) composites perform notably better than various conventional metallic materials. The qualities of the matrix can be changed to enhance the characterization of FRP composites. The mechanical qualities of FRP composites have risen as a result of significant advancements in the
Haider, Rehan, Singh, Pradeep Kumar, Sharma, Kamal
Role of Different Reinforcements in Aluminium 7075-Based Metal Matrix Composite—A Review05-17-04-00257/1/2024
Demands for new materials with superior properties are rising as technological advancement is speeding up globally. Composite materials are gaining popularity due to their enhanced mechanical properties over metal and alloys. Aluminum metal matrix composites (MMCs) are becoming popular in several areas of application such as aerospace, automobile, armed forces, and other commercial applications due to their lightweight, increased strength, better fracture toughness, stiffness, corrosion resistance, and cost-effectiveness. The present study reviews the effects of different reinforcements on MMC materials. The main aim of the present work is to give a clear idea to the readers about the role of individual reinforcement in Al7075-based MMCs. Also, the details of weight% and size of different reinforcement are provided, which will help the readers in their future works. It has been observed that inorganic reinforcements give better mechanical and wear properties to composite materials. For
Kumar, Randhir, Mondal, Sharifuddin
Prediction of Tribological Behavior of Acrylonitrile Butadiene Styrene Polymer Matrix Composites Employing Copper Powders05-17-04-00266/27/2024
This research examines the impact of different amounts of copper (Cu) powder on the wear characteristics of acrylonitrile butadiene styrene (ABS)–Cu composites. Various formulations of ABS–Cu composites have been produced using injection molding, with different amounts of surfactant. Wear properties were evaluated by conducting tribological testing in accordance with ASTM standards. The findings indicated a decrease in wear loss, particularly when using a mixture consisting of 23% ABS, 70% Cu, and 7% surfactant. Machine learning regression algorithms successfully forecasted wear behavior with R-squared values over 0.97. The models used in the analysis included linear, stepwise linear, tree, support vector machine (SVM), efficient linear, Gaussian progression, ensemble, and neural network regression models. This research emphasizes the significance of composite materials in fulfilling contemporary technical requirements. The acquired insights enable the development of materials with
Jatti, Vijaykumar S., Saiyathibrahim, A., Murali Krishnan, R., Balaji, K.
A Methodology for Accelerated Thermo-Mechanical Fatigue Life Evaluation of Advanced Composites2024-26-04216/1/2024
Thermo-mechanical fatigue and natural aging due to environmental conditions are challenging to simulate in an actual test with advanced fiber-reinforced composites, where their fatigue and aging behavior are little understood. Predictive modeling of these processes is challenging. Thermal cyclic tests take a prohibitively long time, although the strain rate effect can be scaled well for accelerating the mechanical stress cycles. Glass fabric composites have important applications in pipes, aircraft, and spacecraft structures, including microwave transparent structures, impact-resistant parts of the wing, fuselage deck and many other load-bearing structures. Often additional additively manufactured features and coatings on glass fabric composites are employed for thermal and anti-corrosion insulations. In this paper, we employ a thermo-mechanical fatigue model based on an accelerated fatigue test and life prediction under hot-to-cold cycles. Thermo-mechanical strain-controlled stress
Kancherla, Kishore Babu, B S, Dakshayini, Raju, Benjamin, Roy Mahapatra, Debiprosad
‘Nanostitches’ Enable Lighter and Tougher Composite Materials24AERP06_106/1/2024
In research that may lead to advancements in the design of next-generation airplane and spacecraft, MIT engineers used carbon nanotubes to prevent cracking in multilayered composites. Massachusetts Institute of Technology, Cambridge, MA 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. But composite materials have one main vulnerability: the space between layers, which is typically filled with polymer “glue” to bond the layers together. In the event of an impact or strike, cracks can easily spread between layers and weaken the material, even though there may be no visible damage to the layers themselves. Over time, as these hidden cracks spread between layers, the composite
‘Nanostitches’ Enable Lighter and Tougher Composite MaterialsTBMG-508686/1/2024
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.
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