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Advanced Composite Material Design and Manufacturing Technology for Aerospace Engineering (2nd Edition)

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Advanced Composites".

Deadline for manuscript submissions: closed (20 July 2024) | Viewed by 11443

Special Issue Editors


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Guest Editor
School of Transportation Science and Engineering, Beihang University, Beijing, 100191, China
Interests: structural design and fabrication technology of advanced composites; aerospace foldable/deployable flexible composite structures (large elastic deformation, large shape memory deformation, inflatable deployment, etc.); composite structures for morphing applications; constitutive of braided composites; damage failure behavior of composite structures; 3D and 4D printed composites; multi objective optimization design
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Guest Editor
Science and Technology on Advanced Composites Laboratory, BIAM, AVIC Composite Center, AVIC Composite Corporation LTD, Beijing 100095, China
Interests: polymer matrix composites; thermoplastic composite; liquid composite molding; composite manufacturing processes
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Guest Editor
School of Automation Science and Electrical Engineering, Beihang University, Beijing 100191, China
Interests: precision detection and control technology of pneumatic transmission system; airborne electromechanical system;intelligent manufacturing; special material processing;aviation oxygen supply technology
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Guest Editor
School of Aeronautics Science and Engineering, Beihang University, Beijing 100191, China
Interests: composite aircraft design and control; aeroelasticity; smart structure; analysis of functional integrated structure
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Guest Editor
Department of Civil, Chemical, Environmental, and Materials Engineering, University of Bologna, Viale del Risorgimento 2, 40136 Bologna, Italy
Interests: modeling of offshore structures and offshore structural components; structural theories of plates and applied mathematical modeling; mechanics of solids and structures; study of composite laminated structures and advanced composite materials; fracture mechanics and crack propagation and initiation; applied numerical methods such as finite element method and mesh-free element method
Special Issues, Collections and Topics in MDPI journals
School of Transportation Science and Engineering, Beihang University, Beijing 100191, China
Interests: structure crashworthiness; impact dynamics; finite element simulation
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Advanced composites have many advantages, such as a high specific strength, high specific modulus, fatigue resistance, light weight, corrosion resistance, strong design, etc. They have been widely investigated and applied in the aerospace field. The amount of composite materials used has become an important indicator for evaluating the advanced nature of aircraft or spacecraft. Composite materials and structures are formed simultaneously, which requires designers to have sufficient understanding of materials, preparation technology, mechanics, etc. Only in this way can we fully explore the potential of composite materials through an appropriate design. The extreme demands in the field of aerospace engineering create new challenges that are good opportunities for the development of advanced composite technology.

This Special Issue is on advanced composite design and manufacturing technology for aerospace engineering, with a main focus on materials, mechanics, manufacturing technology, test characterization, advanced equipment, engineering applications, etc. We encourage submissions of original research papers, short communications and review articles. This Special Issue will report on the latest progress regarding advanced composite technology in the aerospace field.

Potential topics for submissions include, but are not limited to:

  • Material design, such as fiber, resin, interfaces, functional materials, etc.;
  • Mechanical design, such as constitutive modeling, multiscale modeling, stiffness, static strength, fatigue, buckling stability, progressive damage behavior, etc.;
  • Manufacturing technology, such as autoclave, RTM, additive manufacturing, intelligent manufacturing, etc.;
  • Advanced equipment, such as automatic molding, additive manufacturing, test characterization, nondestructive testing, etc.;
  • Engineering applications, such as composite products, high-performance materials, design and evaluation methods, etc.

Dr. Jiangbo Bai
Prof. Dr. Jianwen Bao
Prof. Dr. Yan Shi
Dr. Changchuan Xie
Dr. Nicholas Fantuzzi
Dr. Dayong Hu
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • fiber
  • resin
  • interface
  • composites
  • constitutive model
  • multiscale modeling
  • stiffness
  • static strength
  • fatigue
  • buckling stability
  • progressive damage behavior
  • autoclave
  • RTM
  • additive manufacturing
  • intelligent manufacturing
  • characterization
  • nondestructive testing
  • structural design
  • aeroelasticity
  • smart structures
  • functional structures
  • optimization algorithm
  • machine learning algorithm
  • optimal design

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Published Papers (9 papers)

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Research

12 pages, 3960 KiB  
Article
Thermomechanical Properties of Ramie Fiber/Degradable Epoxy Resin Composites and Their Performance on Cylinder Inner Lining
by Jingqi Geng, Jiale Lyu and Yingchun Cai
Materials 2024, 17(19), 4802; https://doi.org/10.3390/ma17194802 - 29 Sep 2024
Abstract
Type IV gas cylinders are widely used in the field of vehicles due to their advantages such as light weight, cleanliness, and low cost. Ramie fiber/degradable epoxy resin composites (RFRDE) provide new ideas for the material selection of Type IV gas cylinders due [...] Read more.
Type IV gas cylinders are widely used in the field of vehicles due to their advantages such as light weight, cleanliness, and low cost. Ramie fiber/degradable epoxy resin composites (RFRDE) provide new ideas for the material selection of Type IV gas cylinders due to their advantages of low carbon emissions, low environmental pollution, and renewable resource utilization. However, the poor interfacial bonding strength and moisture resistance between polyethylene plastics and RFRDE have limited their application areas. This study tested the mechanical properties of ramie fibers at different heat treatment temperatures, and studied the thermal mechanical properties of RFRDE through differential scanning calorimeter and curing kinetics methods. At 180 °C, the tensile strength of fiber bundles decreased by 34% compared to untreated fibers. As the highest curing temperature decreases, the tensile strength of RFRDE increases but the curing degree decreases. At the highest curing temperature of 100 °C, the tensile strength of RFRDE is 296 MPa. The effect of the corona discharge and flexible adhesive on the surface modification of polyethylene was analyzed using scanning electron microscopy. These results provide guidance for the development of natural fiber/degradable epoxy resin composite materials. Full article
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16 pages, 5268 KiB  
Article
Experimental Tests and Numerical Analysis of Aerodynamic Properties of the Composite-Made Jet-Propelled Aerial Target
by Michał Frant, Łukasz Kiszkowiak, Maciej Majcher and Piotr Zalewski
Materials 2024, 17(14), 3575; https://doi.org/10.3390/ma17143575 - 19 Jul 2024
Viewed by 452
Abstract
The design of an aircraft’s internal structure, and therefore the appropriate choice of material type, is a direct function of the performed tasks and the magnitude and type of the acting loads. The design of a durable aircraft structure with appropriate stiffness and [...] Read more.
The design of an aircraft’s internal structure, and therefore the appropriate choice of material type, is a direct function of the performed tasks and the magnitude and type of the acting loads. The design of a durable aircraft structure with appropriate stiffness and lightness requires knowledge of the loads that will be applied to the structure. Therefore, this paper presents the results of an aerodynamic experimental test and numerical analysis of a newly designed jet-propelled aerial target. The experimental tests were carried out in a low-speed wind tunnel for a wide range of angles of attack and sideslips. Moreover, they were performed for various configurations of the airplane model. In addition, the results of the experimental test were supplemented with the results of the numerical analysis performed using computational fluid dynamics methods. During numerical analysis, specialized software based on solving partial differential equations using the Finite Volumes Method was used. This article presents the methodology of the conducted research. The results of the aerodynamic analysis are presented in the form of diagrams showing the aerodynamic force and moment components as a function of the angle of attack and sideslip. In addition, qualitative results of the flow around the plane have been presented. The results obtained prove that the adopted methods are sufficient to solve these types of problem. The aerial system was positively verified during the qualification tests of the system at the Polish Air Force training range and finally received the type certificate. Full article
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13 pages, 8437 KiB  
Article
The Effect of Cr Addition on the Strength and High Temperature Oxidation Resistance of Y2O3 Dispersion Strengthened Mo Composites
by Haochen Guan, Chongshan Lv, Qingming Ding, Guangda Wang, Ning Xiong and Zhangjian Zhou
Materials 2024, 17(11), 2550; https://doi.org/10.3390/ma17112550 - 25 May 2024
Viewed by 524
Abstract
Y2O3 dispersion-strengthened Molybdenum (Mo) composites were prepared by the mechanical alloying of Mo and Y powders then consolidation by spark plasma sintering. The effects of Chromium (Cr) addition (0 wt. %, 5 wt. %, 10 wt. % and 15 wt. [...] Read more.
Y2O3 dispersion-strengthened Molybdenum (Mo) composites were prepared by the mechanical alloying of Mo and Y powders then consolidation by spark plasma sintering. The effects of Chromium (Cr) addition (0 wt. %, 5 wt. %, 10 wt. % and 15 wt. %, respectively) on the mechanical performance and high-temperature oxidation resistance of Mo-Y2O3 were investigated. The introduction of Cr had a significant influence on the mechanical property and oxidation resistance of the Mo-Y2O3 composite. The highest bending strength reached 932 MPa when the addition of Cr content was 5 wt. % (Mo–5Cr–1Y sample). This improvement is likely attributable to the dual mechanism of grain refinement and solid solution strengthening. Moreover, the Mo–5Cr–1Y sample showed the thinnest oxide layer thickness after high-temperature oxidation tests, and exhibited the best oxidation resistance performance compared with the other samples. First principle calculation reveals that Cr could improve the Mo–MoO3 interface bonding to prevent rapid spalling of the oxide layer. Meanwhile, Cr also facilitates the formation of the dense Cr2(MoO4)3 layer on the surface, which can inhibit further oxidation. Full article
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15 pages, 7505 KiB  
Article
Research and Validation of CF/PEEK-Based Truss Rod Crimping and Pultruding Process for On-Orbit Isoform Forming
by Jiayong Yan, Peng Li, Chao Geng, Xuanyu Guo and Lixin Zhang
Materials 2024, 17(10), 2393; https://doi.org/10.3390/ma17102393 - 16 May 2024
Viewed by 628
Abstract
A crimping and pultruding forming process for truss rods using Carbon Fiber (CF)/Polyether–Ether–Ketone (PEEK) prepreg tape as the raw material is proposed to address the problem of continuous manufacturing of space trusses on orbit. The proposed process provides material rods for continuous truss [...] Read more.
A crimping and pultruding forming process for truss rods using Carbon Fiber (CF)/Polyether–Ether–Ketone (PEEK) prepreg tape as the raw material is proposed to address the problem of continuous manufacturing of space trusses on orbit. The proposed process provides material rods for continuous truss manufacturing. Through numerical simulation and experimental verification, the effects of relevant parameters on the forming process are determined, an efficient method of rod curl pultrusion, in-rail, equal material forming is proposed, and the structural configuration of the rod curl pultrusion forming mold is determined. The equivalent macroscopic mechanical properties of unidirectional CF/PEEK prepreg strips are considered, and the rod-forming process is investigated. Rod samples with different process parameters are prepared, and several tests are conducted on them. The results show that the forming load pull is negatively correlated with the temperature at the same forming speed, and forming speed is positively correlated with the forming load pull at a certain temperature. Temperature and speed affect the surface quality of the rod, the density of the material filling, and the mechanical properties of the rod. The optimal forming process parameters are determined through numerical simulation and experimental verification. The developed molding technology has the advantages of high efficiency, low energy consumption, and high integration. It reduces manufacturing costs and improves manufacturing efficiency, so it can serve as a new and effective solution for the manufacturing of high-performance truss rods in the aerospace field. Full article
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13 pages, 6741 KiB  
Article
Influence of the Second-Phase Resin Structure on the Interfacial Shear Strength of Carbon Fiber/Epoxy Resin
by Hansong Liu, Jinsong Sun, Lianwang Zhang, Zhaobo Liu, Chengyu Huang, Mingchen Sun, Ziqi Duan, Wenge Wang, Xiangyu Zhong and Jianwen Bao
Materials 2024, 17(6), 1323; https://doi.org/10.3390/ma17061323 - 13 Mar 2024
Cited by 3 | Viewed by 871
Abstract
The toughening modification of epoxy resin has received widespread attention. The addition of the second-phase resin has a good toughening effect on epoxy resin. In order to investigate the effect of the second-phase resin on the interphase of composites, in this work the [...] Read more.
The toughening modification of epoxy resin has received widespread attention. The addition of the second-phase resin has a good toughening effect on epoxy resin. In order to investigate the effect of the second-phase resin on the interphase of composites, in this work the interfacial properties of carbon fiber (CF)/epoxy resin with the second-phase resin structure were investigated. Methodologies including surface structure observation, chemical characteristics, surface energy of the CF, and micro-phase structure characterization of resin were tested, followed by the micro-interfacial performance of CF/epoxy composites before and after hygrothermal treatment. The results revealed that the sizing process has the positive effect of increasing the interfacial bonding properties of CF/epoxy. From the interfacial shear strength (IFSS) test, the introduction of the second phase in the resin reduced the interfacial bonding performance between the CF and epoxy. After the hygrothermal treatment, water molecules diffused along the interfacial paths between the two resins, which in turn created defects and consequently brought about a reduction in the IFSS. Full article
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11 pages, 5509 KiB  
Article
A Comparative Study on Rice Husk, as Agricultural Waste, in the Production of Silica Nanoparticles via Different Methods
by Shengwang Yuan, Yihao Hou, Shun Liu and Yunhai Ma
Materials 2024, 17(6), 1271; https://doi.org/10.3390/ma17061271 - 9 Mar 2024
Cited by 1 | Viewed by 1628
Abstract
This study explores the conversion of agricultural waste into valuable industrial precursors, specifically focusing on the production of silica nanoparticles from rice husk (RH) via calcination and sol–gel processes. The synthesized particles underwent detailed analysis to assess their chemical composition, structural features, morphological [...] Read more.
This study explores the conversion of agricultural waste into valuable industrial precursors, specifically focusing on the production of silica nanoparticles from rice husk (RH) via calcination and sol–gel processes. The synthesized particles underwent detailed analysis to assess their chemical composition, structural features, morphological characteristics, and size distribution. This comparative analysis evaluates the effectiveness of various methods in generating silica from RH and examines the impact of different drying techniques, including freeze-drying and conventional thermal drying, on the properties of the resulting silica nanoparticles. Utilizing a combination of sol–gel and freeze-drying techniques produced spherical nanoparticles with diameters of 10 to 20 nm, characterized by size uniformity, clear contours, and minimal aggregation. X-ray diffraction (XRD) analysis identified the amorphous nature of the silica, as evidenced by diffraction peaks typical of amorphous silica in the RH-derived samples processed via different methods. Significantly, the XRD patterns of the calcination-derived silica showed no foreign peaks, indicating a purer amorphous state. The findings of this study are anticipated to contribute to the development of innovative and efficient silica nanomaterials, fostering the sustainable use of agricultural waste. Full article
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14 pages, 5980 KiB  
Article
Porous Polymer Structures with Tunable Mechanical Properties Using a Water Emulsion Ink
by Joshua Z. R. Dantzler, Sofia Gabriela Gomez, Stephanie Gonzalez, Diego Gonzalez, Alan O. Loera Martinez, Cory Marquez, Md Sahid Hassan, Saqlain Zaman, Alexis Lopez, Md Shahjahan Mahmud and Yirong Lin
Materials 2024, 17(5), 1074; https://doi.org/10.3390/ma17051074 - 26 Feb 2024
Cited by 1 | Viewed by 974
Abstract
Recently, the manufacturing of porous polydimethylsiloxane (PDMS) with engineered porosity has gained considerable interest due to its tunable material properties and diverse applications. An innovative approach to control the porosity of PDMS is to use transient liquid phase water to improve its mechanical [...] Read more.
Recently, the manufacturing of porous polydimethylsiloxane (PDMS) with engineered porosity has gained considerable interest due to its tunable material properties and diverse applications. An innovative approach to control the porosity of PDMS is to use transient liquid phase water to improve its mechanical properties, which has been explored in this work. Adjusting the ratios of deionized water to the PDMS precursor during blending and subsequent curing processes allows for controlled porosity, yielding water emulsion foam with tailored properties. The PDMS-to-water weight ratios were engineered ranging from 100:0 to 10:90, with the 65:35 specimen exhibiting the best mechanical properties with a Young’s Modulus of 1.17 MPa, energy absorption of 0.33 MPa, and compressive strength of 3.50 MPa. This led to a porous sample exhibiting a 31.46% increase in the modulus of elasticity over a bulk PDMS sample. Dowsil SE 1700 was then added, improving the storage capabilities of the precursor. The optimal storage temperature was probed, with −60 °C resulting in great pore stability throughout a three-week duration. The possibility of using these water emulsion foams for paste extrusion additive manufacturing (AM) was also analyzed by implementing a rheological modifier, fumed silica. Fumed silica’s impact on viscosity was examined, revealing that 9 wt% of silica demonstrates optimal rheological behaviors for AM, bearing a viscosity of 10,290 Pa·s while demonstrating shear-thinning and thixotropic behavior. This study suggests that water can be used as pore-formers for PDMS in conjunction with AM to produce engineered materials and structures for aerospace, medical, and defense industries as sensors, microfluidic devices, and lightweight structures. Full article
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16 pages, 4388 KiB  
Article
Durability Analysis of CFRP Adhesive Joints: A Study Based on Entropy Damage Modeling Using FEM
by Yutong Li, Huachao Deng, Maruri Takamura and Jun Koyanagi
Materials 2023, 16(20), 6821; https://doi.org/10.3390/ma16206821 - 23 Oct 2023
Cited by 2 | Viewed by 1161
Abstract
Experimental methodologies for fatigue lifetime prediction are time-intensive and susceptible to environmental variables. Although the cohesive zone model is popular for predicting adhesive fatigue lifetime, entropy-based methods have also displayed potential. This study aims to (1) provide an understanding of the durability characteristics [...] Read more.
Experimental methodologies for fatigue lifetime prediction are time-intensive and susceptible to environmental variables. Although the cohesive zone model is popular for predicting adhesive fatigue lifetime, entropy-based methods have also displayed potential. This study aims to (1) provide an understanding of the durability characteristics of carbon fiber-reinforced plastic (CFRP) adhesive joints by incorporating an entropy damage model within the context of the finite element method and (2) examine the effects of different adhesive layer thicknesses on single-lap shear models. As the thickness of the adhesive layer increases, damage variables initially increase and then decrease. These peak at 0.3 mm. This observation provides a crucial understanding of the stress behavior at the resin–CFRP interface and the fatigue mechanisms of the resin. Full article
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14 pages, 7542 KiB  
Article
Preparation and Validation of a Longitudinally and Transversely Stiffened Panel Based on Hybrid RTM Composite Materials
by Weidong Li, Zhengzheng Ma, Pengfei Shen, Chuyang Luo, Xiangyu Zhong, Shicai Jiang, Weihua Bai, Luping Xie, Xiaolan Hu and Jianwen Bao
Materials 2023, 16(14), 5156; https://doi.org/10.3390/ma16145156 - 21 Jul 2023
Cited by 1 | Viewed by 3058
Abstract
In the face of the difficulty in achieving high-quality integrated molding of longitudinally and transversely stiffened panels for helicopters by resin-matrix composite materials, we combine the prepreg process and the resin transfer molding (RTM) process to propose a hybrid resin transfer molding (HRTM) [...] Read more.
In the face of the difficulty in achieving high-quality integrated molding of longitudinally and transversely stiffened panels for helicopters by resin-matrix composite materials, we combine the prepreg process and the resin transfer molding (RTM) process to propose a hybrid resin transfer molding (HRTM) for composite stiffened panel structures. The HRTM process uses a mixture of prepreg and dry fabric to lay up a hybrid fiber preform, and involves injecting liquid resin technology. Using this process, a longitudinally and transversely stiffened panel structure is prepared, and the failure modes under compressive load are explored. The results show that at the injection temperature of the RTM resin, the prepreg resin dissolves slightly and has little effect on the viscosity of the RTM resin. Both resins have good miscibility at the curing temperature, which allows for the overall curing of the resin. A removable box core mold for the HRTM molding is designed, which makes it convenient for the mold to be removed after molding and is suitable for the overall molding of the composite stiffened panel. Ultrasonic C-scan results show that the internal quality of the composite laminates prepared using the HRTM process is good. A compression test proves that the composite stiffened panel undergoes sequential buckling deformation in different areas under compressive load, followed by localized debonding and delamination of the skin, and finally failure due to the fracture of the longitudinal reinforcement ribs on both sides. The compressive performance of the test specimen is in good agreement with the finite element simulation results. The verification results show that the HRTM process can achieve high-quality integrated molding of the composite longitudinally and transversely stiffened panel structure. Full article
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