Rourkela: Researchers at the National Institute of Technology (NIT) Rourkela have secured an Indian patent (Patent No. 596943) for an innovative composite manufacturing technology that significantly improves the strength, durability and damage resistance of Fibre-Reinforced Polymer (FRP) composites, paving the way for next-generation lightweight engineering materials.
The patented innovation was developed by the FRP Composite Lab of the Department of Metallurgical and Materials Engineering at NIT Rourkela through collaborative research involving Dr. Rajesh Kumar Prusty (Assistant Professor), Prof. Bankim Chandra Ray (Professor), research scholar Mr. Parimal Jana, and Dr. Dinesh Kumar Rathore from the Department of Mechanical Engineering at MNIT Jaipur.
Breakthrough in Composite Manufacturing
FRP composites are widely used in industries such as aerospace, defence, automotive, renewable energy, marine engineering and hydrogen storage because of their excellent strength-to-weight ratio, corrosion resistance and design flexibility. However, these materials are susceptible to damage over time due to repeated loading, leading to cracks, delamination and reduced structural performance.
To overcome these challenges, the research team developed a three-dimensional reinforced hybrid composite by integrating glass fibres with graphene nanoplatelets aligned through the thickness of the material during manufacturing.
The innovation introduces a simple modification to conventional composite fabrication techniques by applying a 50 Hz AC electric field at 800 volts during the curing process. This process enables the controlled alignment of unmodified graphene nanoplatelets within glass fibre-reinforced epoxy composites while remaining compatible with existing industrial manufacturing methods.
Significant Improvement in Mechanical Performance
Laboratory evaluations conducted according to ASTM standards demonstrated remarkable improvements in the mechanical properties of the newly developed composites.
The technology achieved:
- 37% increase in tensile strength
- 30% improvement in flexural strength
- 63% increase in flexural modulus
- 26% improvement in tensile modulus
- 24% increase in interlaminar shear strength
- 33% improvement in Mode-I fracture toughness
- 53% increase in Mode-II fracture toughness
- 55% higher storage modulus at 40°C
These enhancements make the composite significantly stronger, more durable and more resistant to structural damage under demanding operating conditions.
Wide Range of Industrial Applications
According to Dr. Rajesh Kumar Prusty, the technology has immense potential across multiple high-performance engineering sectors.
Potential applications include:
- Aircraft structures and panels
- Automotive crash-resistant components
- Wind turbine blades
- Pressure vessels
- Marine structures
- Defence platforms
- Space launch vehicles
- Other lightweight yet damage-tolerant engineering components
The improved mechanical properties are expected to enhance product reliability while reducing maintenance requirements.
Supporting Sustainable Manufacturing
Prof. Bankim Chandra Ray said the innovation could contribute significantly towards reducing maintenance costs, improving energy efficiency and promoting sustainable manufacturing practices.
He noted that the technology aligns with the objectives of Atmanirbhar Bharat by strengthening India’s capabilities in advanced materials research and indigenous manufacturing.
Next Phase of Development
Following the successful patent, the research team plans to validate the material in larger structural components and study its long-term environmental durability under real-world operating conditions.
The researchers are also exploring technology licensing opportunities and collaborations with industry partners to facilitate commercial deployment across aerospace, automotive, renewable energy and other advanced manufacturing sectors.
The patented technology marks another significant achievement for NIT Rourkela, highlighting the institute’s growing contribution to cutting-edge materials research and the development of innovative engineering solutions for high-performance applications.
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