Rourkela, July 31: Researchers from National Institute of Technology Rourkela have secured a patent for a composite manufacturing technology that can increase the strength, and durability of Fiber-Reinforced Polymer composites. The developed technology represents a major milestone in composite materials for high-performance engineering applications.
This research outcome is the manifestation of the continuous collaborative work of the team of FRP Composite Lab of the Department of Metallurgical and Materials Engineering at NIT Rourkela, comprising of Dr. Rajesh Kumar Prusty, Assistant Professor, and Prof. Bankim Chandra Ray, Professor, and Mr. Parimal Jana, Research Scholar, along with Dr. Dinesh Kumar Rathore from the Department of Mechanical Engineering at MNIT Jaipur.
Fibre-Reinforced Polymer composites have exceptional strength-to-weight ratio, fatigue resistance, design flexibility and excellent corrosion resistance, making them suitable across wide spectrum of engineering applications. While 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, 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 has 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. This 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.
A key feature 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.
Speaking about the real-world applications of the developed innovation, Dr. Rajesh Kumar Prusty, Assistant Professor, NIT Rourkela, said,
“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.”
Based on the lab-scale tests, the research team found the developed FRP composites to be of superior quality. Experimental evaluations conducted according to ASTM standards recorded:
- 37% increase in tensile strength
- 30% improvement in flexural strength
- 63% increase in flexural modulus
- 26% improvement in tensile modulus
- 24% improvement in interlaminar shear strength
- 33% increase in Mode-I fracture toughness
- 53% increase in Mode-II fracture toughness
- 55% higher storage modulus at 40°C
Speaking about the significance of the innovation, Prof. Bankim Chandra Ray, Professor, NIT Rourkela, said,
“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.”
As the next step, the research team plans to test developed material in larger structural components and evaluate its long-term environmental durability. Additionally, the team is pursuing technology licensing and industry collaboration to bring this innovation from the lab to the market.
