Composite Materials for Aerospace

How do materials fail, and how can we design stronger, tougher, and more resilient ones? Published in #PNAS, our physics-aware AI model integrates advanced reasoning, rational thinking, and strategic planning capabilities models with the ability to write and execute code, perform atomistic simulations to solicit new physics data from “first principles”, and conduct visual analysis of graphed results and molecular mechanisms. By employing a multiagent strategy, these capabilities are combined into an intelligent system designed to solve complex scientific analysis and design tasks, as applied here to alloy design and discovery. This is significant because our model overcomes the limitations of traditional data-driven approaches by integrating diverse AI capabilities—reasoning, simulations, and multimodal analysis—into a collaborative system, enabling autonomous, adaptive, and efficient solutions to complex, multiobjective materials design problems that were previously slow, expert-dependent, and domain-specific. Wonderful work by my postdoc Alireza Ghafarollahi! Background: The design of new alloys is a multiscale problem that requires a holistic approach that involves retrieving relevant knowledge, applying advanced computational methods, conducting experimental validations, and analyzing the results, a process that is typically slow and reserved for human experts. Machine learning can help accelerate this process, for instance, through the use of deep surrogate models that connect structural and chemical features to material properties, or vice versa. However, existing data-driven models often target specific material objectives, offering limited flexibility to integrate out-of-domain knowledge and cannot adapt to new, unforeseen challenges. Our model overcomes these limitations by leveraging the distinct capabilities of multiple AI agents that collaborate autonomously within a dynamic environment to solve complex materials design tasks. The proposed physics-aware generative AI platform, AtomAgents, synergizes the intelligence of LLMs and the dynamic collaboration among AI agents with expertise in various domains, incl. knowledge retrieval, multimodal data integration, physics-based simulations, and comprehensive results analysis across modalities. The concerted effort of the multiagent system allows for addressing complex materials design problems, as demonstrated by examples that include autonomously designing metallic alloys with enhanced properties compared to their pure counterparts. We demonstrate accurate prediction of key characteristics across alloys and highlight the crucial role of solid solution alloying to steer the development of alloys. Paper: https://lnkd.in/enusweMf Code: https://lnkd.in/eWv2eKwS MIT Schwarzman College of Computing MIT Civil and Environmental Engineering MIT Department of Mechanical Engineering (MechE) MIT Industrial Liaison Program MIT School of Engineering

Around 2nd world war wood used to be the material of choice for construction of passenger coaches . Gradually steel crawled into the construction space for manufacture of coaches , with alloy steel in various AVTARS like CORTEN etc . By eighties , STAINLESS STEEL had started becoming the metal of choice for construction of passenger coaches. ALUMINIUM with its light weight advantages was sure to found traction and in most of the advanced Railways with increasing speeds , it has become the most preferred material for Rail coach construction. The material often regarded as the “future material for railway rolling stock” is composite materials, particularly carbon fiber reinforced polymers (CFRP) and glass fiber reinforced polymers (GFRP). These materials are considered groundbreaking due to their combination of strength, lightweight properties, durability, and resistance to corrosion, which contribute to efficiency and safety improvements in modern rail systems. Key Materials Gaining Attention: 1. Aluminum Alloys: Lightweight yet strong, providing a good balance of strength and weight. Easier to recycle compared to some composites. Commonly used in high-speed trains for their aerodynamic profiles and lightweight benefits. 2. Carbon Fiber Reinforced Polymer (CFRP): High strength-to-weight ratio, making trains lighter and more energy-efficient. Corrosion-resistant and requires less maintenance. Enables sleek, aerodynamic designs due to its moldability. 3. Glass Fiber Reinforced Polymer (GFRP): More cost-effective than carbon fiber, though slightly heavier. Resistant to fatigue and environmental factors. Used in non-structural components like interior panels and flooring. 4. High-Strength Steel Alloys: Improvements in steel production are leading to lighter yet stronger steel options. Retains the crashworthiness and durability needed for safety. Affordable and recyclable, making it a practical choice for many railway applications. 5. Titanium Alloys: Extremely strong and lightweight. Excellent corrosion resistance, especially useful in extreme weather conditions. High cost, limiting its use to specialized applications, like connectors or critical structural parts. Why Composites Are Leading the Future: Weight Reduction: Lighter materials lead to energy savings, lower operational costs, and higher speeds. Design Flexibility: Composites allow more freedom in shape, improving aerodynamics and aesthetics. Maintenance and Longevity: Reduced corrosion and longer life cycles lower maintenance requirements. Sustainability: With advances in recyclable composites, these materials can be environmentally friendly. Given the ongoing research in materials science, it’s likely that a mix of high-strength, lightweight alloys and advanced composites will dominate future rolling stock designs, each chosen based on specific application needs—whether structural integrity, aerodynamics, or cost-efficiency. #rollingstock #railway

🚧 𝙂𝙁𝙍𝙋 𝘽𝙖𝙧𝙨 — 𝘼𝙧𝙚 𝙏𝙝𝙚𝙮 𝙩𝙝𝙚 𝙁𝙪𝙩𝙪𝙧𝙚 𝙤𝙛 𝙍𝙚𝙞𝙣𝙛𝙤𝙧𝙘𝙚𝙢𝙚𝙣𝙩? Steel has been the backbone of RCC for over a century. But in corrosive and high-performance environments, GFRP (Glass Fiber Reinforced Polymer) bars are fast becoming a smart alternative. 🧠 𝙒𝙝𝙖𝙩 𝙞𝙨 𝙂𝙁𝙍𝙋? GFRP bars are made from glass fibers embedded in a polymer matrix — They’re non-metallic, corrosion-resistant, and incredibly strong for their weight. ✅ Advantages of GFRP Bars: Non-corrosive – No rust, no maintenance, ideal for coastal & chemical zones Lightweight – 1/4th the weight of steel, easy to transport & handle High tensile strength – Up to 2x that of mild steel EMI/RFI transparent – Perfect for hospitals, labs & rail infrastructure Longer lifespan – Less deterioration, even in aggressive environments Thermally non-conductive – Good for temperature-sensitive zones ❌ Limitations of GFRP Bars: ❗ Lower modulus of elasticity – More flexible than steel, which may cause excessive deflection if not designed properly ❗ No plastic deformation – Brittle failure; no visual warning before failure ❗ Not suitable for all structures – Needs engineering judgment ❗ Higher initial cost – Though lifecycle cost is lower ❗ Limited awareness & skilled detailing – Especially in traditional workflows 🏭 Manufacturers of GFRP Bars 🌍 Global Players: Owens Corning (USA) Aslan FRP (USA) @Schoeck (Germany) 🇮🇳 Indian Companies: iBull | GFRP Rebar Manufacturing Company – Leading Indian GFRP bar manufacturer ReforceTech™ – GFRP & Basalt FRP systems Jindal FRP – Customized GFRP for infrastructure and industry 🧱 Common Use Cases: Coastal infrastructure Bridges, culverts, tunnels Chemical plants, WTPs Hospital & metro construction Lightweight slabs & precast members 💡 GFRP is not a replacement for all steel — but it’s a superior option in the right context. If you're a structural engineer, contractor, or developer working in aggressive environments — it’s time to explore GFRP seriously. 💬 Have you used GFRP in your projects? Drop your experience or questions below 👇 Follow Civil Engineer DK for more such contents #GFRP #Reinforcement #CivilEngineering #ConcreteInnovation #SteelAlternative #ConstructionMaterials #IBull #OwensCorning #ReforceTech #SiteExecution #StructuralDesign #CivilEngineerDK #LinkedInForEngineers #MaterialScience #EngineeringInsights #ConstructionTrends2025

To achieve net zero, we must develop damage tolerant structures that enable the realisation of more efficient aircraft. In my PhD I developed a bio-inspired embedded composite stiffener, manufactured via Automated Fibre Placement (AFP), to address the vulnerability of traditional composite stiffened panels to unstable stiffener debonding. I am pleased to say this work has now been published in Composites Part B Engineering. The full article is available here: ‘A bio-inspired integrated composite stiffened panel for debonding prevention manufactured via AFP’ - https://lnkd.in/eF2tGuyW Composite stiffened panels are a mass efficient method of providing stiffness to structures, however, traditional designs are vulnerable to unstable debonding failure of the stiffeners from the skin. This contributes to conservative certification requirements being necessary, leading to heavier structures. In this work, we propose an embedded composite stiffener, inspired by damage tolerant tree-branch attachments, to eliminate this premature failure mechanism. It is important to ensure that designs are manufacturable with sustainable and industrially relevant methods. In this work we developed and demonstrated a successful manufacturing method for composite stiffened panels with AFP. A video of the manufacturing process can be seen here: https://lnkd.in/eciHZFRN The video below shows the testing of representative specimens, firstly for a traditional design, then our bio-inspired embedded design. The bio-inspired design exhibited a 78% increase in peak load, along with drastic improvements in failure stability and energy absorption. Thank you to my supervisor Silvestre Pinho, and my co-authors: Yifei Yang, Lorenzo Mencattelli, Victor MÉDEAU, and James Finlayson for their support and contributions to this project. Additionally, thank you to Chiemi Avila Mori & Pavel Perrotey from Carbon Axis for their support during the manufacturing development! _________________________________________________ #composites #compositematerials #compositestructures #carbonfiber #aerospace #aerospaceengineering #sustainability #netzero #phd Department of Aeronautics (Imperial) Imperial College London

📡When Fiber Orientation Becomes a Weapon The B‑2 Spirit doesn’t evade radar by magic. It disappears because engineers turned composites into electromagnetic tools. 📡 Radar sends out waves. Metals bounce them back. But with the right fiber angles, resin, and layup⁉️ Composites absorb, scatter, and cancel radar energy. That’s stealth by design. 🔹 CFRP skins → carbon fibers dissipate radar as heat. 🔹 Honeycomb cores → trap waves inside the structure. 🔹 Glass & aramid plies → adjust conductivity and lightning resistance. 🔹 Built-in RAM (Radar Absorbent Material) → not painted, but embedded into the laminate. And the key: 🧠 Automated Fiber Placement (AFP) lets engineers orient each ply with surgical precision — tuning radar behavior like a symphony of reflection control. No fasteners. No seams. Just one continuous radar-dampening shell. Stealth isn’t applied. It’s manufactured. Fiber by fiber. Ply by ply. #FiberOrientationMatters #B2Spirit #StealthTech #AFP #CFRP #CompositeManufacturing #RadarAbsorption #MaterialsScience #LowObservable

There is a cash cow of an opportunity for the companies that can figure out how to make new products out of repurposing wind turbine blades.  Challenges with repurposing the fiberglass blades have led to fields of retired blade graveyards and/or disposal in landfills.  According to NREL, an average of 5500 blades will be retired each year for the next 5 years in the US alone; that figure would increase between 10,000 and 20,000 until 2040. Can you say "Houston, we have a problem"?   Here are 3 US based companies that are figuring out solutions to reduce and repurpose this difficult material:   Carbon Rivers, Inc. This Tennessee-based company has developed a process to recover clean, mechanically intact glass fiber from decommissioned wind turbine blades. The recycled fiberglass is then upcycled into new composite materials, contributing to a circular wind turbine economy. Veolia North America: In partnership with GE Renewable Energy, Veolia processes decommissioned blades by shredding them and incorporating the fiberglass and resin into cement production. This method not only recycles the blade materials but also reduces CO₂ emissions in cement manufacturing by approximately 27%. REGEN Fiber Located in Fairfax, Iowa, Regen Fiber has established a facility capable of processing up to 30,000 tons of wind turbine blades annually. Their proprietary process recycles 100% of the blade materials into fibers and additives that enhance the durability and environmental resistance of concrete and asphalt.   In a country where the DOT loves to temporarily fill or resurface roadways with composites that can't withstand the wear/tear, I love the idea of resins being created that strengthen our building materials with repurposed materials from otherwise wasted products.    What other ways have you heard of these materials being re-purposed?

Happy to share that we have published our latest research work on "Effect of Solution Heat Treatment on Corrosion Performance of Multi-pass Friction Stir Processed AA6061/Ceria-Stabilized Zirconia Composites for Marine Applications," in the Journal of Materials Engineering and Performance (JMEP). This study on ceria-stabilized zirconia (CSZ)-reinforced aluminum matrix composites (AMCs) fabricated using multi-pass friction stir processing (FSP) on AA6061-T6 alloy, with a focus on improving mechanical and corrosion resistance properties. https://lnkd.in/g_DhDztS This approach offers a viable route to enhance AMC performance in aggressive environments like marine and coastal structures. Could be extended to aerospace and automotive applications where both mechanical and corrosion resistance are required. Advanced Materials Manufacturing and Tribology (AM2T) Research Group, IIT Tirupati Research Scholars, Nisar Ahamad Khan, Dipayan Chakraborty, Department of Mechanical Engineering IIT Tirupati

The evolution of composites: When rocket scientists 🚀 turn marine engineers 🚢 In the superyacht industry we are used to dealing with Super HNWIs who continuously demand the most outrageous of features/indicators (usually to outdo each other) like mega yachts that approximate the speed of Tokyo’s Bullet Train in ice conditions, while running on 100% renewable fuel. And so, the poor naval architects are presented with impossible-to-solve (with traditional marine approaches) problems. But then the bravest of shipyards created a trend. They started hiring composites gurus from the aviation and aerospace fields, ‘borrowing’ both tech and know-how from literally out of space 🌌 . Talking about transferable skills … or materials… It makes sense. Aerospace-grade composites achieve an FVF (fiber volume fraction) of 70%! Weight goes down, fuel efficiency is through the roof and environmental impact during operation can lower by 25%. Plus, the structural rigidity is enhanced. NOBISKRUG’s Sailing Yacht A, for example, is reported to withstand double the weight of a Boeing Dreamliner wing. No traditional yachting material can even approximate this type of hull strength-to-weight ratio. But can it go fast? I don’t know about you, but I am yet to see a slow rocket! The epoxy-reinforced-E-glass UHV100 by Lazzara Yachts, for example, reaches speed of 28 knots, while AB Yachts’ AB100 (constructed with fibre-reinforced plastic) can accelerate to 60 knots while maintaining stability, comfort and minimal noise! Finally, let’s not forget that a superyacht is expected to look sexy 👙 These high-performance materials are perfect for creating sleeker designs and, as an added bonus, can boost corrosion resistance. So why are not all modern yacht builders using aerospace-grade composites yet? Oh yes… the cost 💶 Well, yeah, these new materials do cost a pretty penny (about 28% more than natural fibre composites), but we are dealing with HNWIs here, right? And the cherry on top is that demand for PVC-foam based and fibre glass-resin layered materials is now expanding beyond the luxury niche. The EU has committed €85 million to an aerospace-maritime mashup projects already. So, if you are not already upping your composites game, it is a good time to look at all the new stuff on the market. #yachtinnovation #marineengineering #composites

📣 IN-SITU 3D PRINTING OF COMPOSITE MATERIALS! 📣 As originally reported by Colorado State University (CSU, Fort Collins), mechanical engineering professor Mostafa Yourdkhani has been awarded the National Science Foundation (NSF) Faculty Early Career Development Award for his research on advanced manufacturing of composite materials. 🕵🏻♂️ Yourdkhani’s research program at CSU has been focused on 3D printing of composite materials, including carbon fiber. Current methods for producing these composites can be expensive, slow and energy intensive. The video shown above details recent work with his team on in-situ printing and curing of discontinuous fiber-reinforced thermoset composites. The free-from creation hardens on its own as it unfolds on a heated surface, with no mold or structure to hold it in place. Yourdkhani shows the video to illustrate that he and his graduate students have discovered a way to print carbon fiber composites in a very short amount of time with minimal heat! 👏 #composites #composite #compósitos #compositematerials #materialsengineering #fibers #lightweight #reinforcedplastics

Revolutionizing Aircraft Structures: The A380 Hybrid Wing Rib The Airbus A380 is an engineering marvel, and one of the key innovations that contributed to its efficiency is the use of hybrid wing ribs. This image showcases a composite-metal hybrid rib, a crucial component designed to reduce weight while maintaining structural integrity. Why this construction? Traditional wing ribs are typically made from aluminum alloys, providing strength but adding weight. In the case of the A380, engineers incorporated composite materials alongside metal to create a lighter yet durable structure. This hybrid approach leverages: ✔ Weight Reduction: Composites are significantly lighter than aluminum, contributing to fuel efficiency. ✔ Structural Strength: The combination of materials ensures the rib can handle aerodynamic loads effectively. ✔ Corrosion Resistance: Composite materials resist environmental degradation better than metals, enhancing longevity. Significance in Aviation For an aircraft as large as the A380, every kilogram saved translates to improved fuel efficiency, lower operational costs, and reduced environmental impact. The use of hybrid materials in wing ribs exemplifies the evolution of aerospace manufacturing, where weight-saving innovations are critical to performance. This construction method is a testament to the continuous advancements in aviation technology, paving the way for future aircraft designs. #A380 #AerospaceEngineering #CompositeMaterials #AviationInnovation #AircraftDesign #airbus #composite #aviation