Rourkela: National Institute of Technology (NIT) Rourkela researchers have secured a patent (No. 596943) for a composite manufacturing technology that can increase strength and durability of Fiber-Reinforced Polymer (FRP) composites.
It’s a major milestone in composite materials for high-performance engineering applications.
The outcome is the manifestation of the continuous collaborative work of the research team of FRP Composite Lab of the Department of Metallurgical and Materials Engineering at NIT Rourkela — comprising Dr Rajesh Kumar Prusty, Assistant Professor, Prof. Bankim Chandra Ray, Professor, Parimal Jana, Research Scholar, along with Dr Dinesh Kumar Rathore from Department of Mechanical Engineering at MNIT Jaipur.
FRP composites have exceptional strength-to-weight ratio, good fatigue resistance, design flexibility along with excellent corrosion resistance, making them suitable across wide spectrum of engineering applications.
These lightweight yet strong materials are used widely in commercial aircraft, defence platforms, space launch vehicles, high-speed rail, renewable energy systems, and hydrogen storage tanks over time. However, their limitation in withstanding damage under heavy pressure can lead to cracks, separation of layers and reduced performance.
To overcome this limitation, the NIT Rourkela-led research team developed a three-dimensional reinforced composite. This hybrid composite combines glass fibers with graphene nanoplatelets that are aligned through the thickness of the composite during manufacturing. The process creates a stronger internal structure, allowing the fibers, graphene, and epoxy matrix to work together more effectively, resulting in a tougher and more durable composite.
One of the main features of the patented technology is its ability to align unmodified graphene nanoplatelets within glass fibre-reinforced epoxy composites using a simple manufacturing process. With a minor modification in the conventional manufacturing method, the team used a standard 50 Hz AC electric field at 800 volts at the time of curing during the manufacturing process, making this process compatible with commonly used composite manufacturing methods.
“Our technology has wide-ranging applications in sectors where lightweight yet damage-tolerant materials are required. Aircraft panels, automotive crash structures, wind turbine blades, pressure vessels, marine structures, and other advanced engineering components are a few prime examples where our innovation can be directly used,” said Dr Prusty.
Prof. Ray said their technology can lower maintenance costs. “By improving durability while reducing weight, the innovation has the potential to lower maintenance costs, improve energy efficiency, and contribute to sustainable manufacturing practices. Our innovation can play a significant role in supporting India’s Atmanirbhar Bharat mission in advanced materials.”