Advanced materials were used and are being implemented in structural, mechanical, and high-end applications. Contemporary materials are used and being implemented in structural, mechanical, and high-end applications. Composites have several major capabilities, some of them being able to resist fatigue, corrosion-resistance, and production of lightweight components with almost no compromise to the reliability, etc. Nanocomposites are a branch of materials within composites, known for their greater mechanical properties than regular composite materials. The use of nanocomposites in the aerospace industry currently faces a research gap, mainly identifying the future scope for application. Most successes in the aerospace industry are because of the use of suitable nanocomposites. This review article highlights the various nanocomposite materials and their properties, manufacturing methods, and their application, with key emphasis on exploiting their advanced and immense mechanical properties in the aerospace industry. Aerospace structures have used around 120,000 materials; herein, nanocomposites such as MgB2, multi-walled carbon nanotubes, and acrylonitrile butadiene styrene/montmorillonite nanocomposites are discussed, and these highlight properties such as mechanical strength, durability, flame retardancy, chemical resistance, and thermal stability in the aerospace application for lightweight spacecraft structures, coatings against the harsh climate of the space environment, and development of microelectronic subsystems.

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The field of bio-inspired design has tremendously transitioned into newer automated methods, yet there are methods being discovered which can elucidate underlying principles in design, materials, and manufacturing. Bio-inspired design aims to translate knowledge from the natural world to the current trends in industry. The recent growth in additive manufacturing (AM)methods has fueled the tremendous growth of bio-inspired products. It has enabled the production of intricate and complicated features notably used in the aerospace industry. Numerous methodologies were adopted to analyse the process of bio-inspired material selection, manufacturing methods, design, and applications. In the current review, different approaches are implemented to utilize bio-inspired designs that have revolutionized the aerospace industry, focusing on AM methods.

Purpose The purpose of this paper is to implement the generative design as an optimization technique to achieve a reasonable trade-off between weight and reliability for the control arm plate of a double-wishbone suspension assembly of a Formula Student race car. Design/methodology/approach The generative design methodology is applied to develop a low-weight design alternative to a standard control arm plate design. A static stress simulation and a fatigue life study are developed to assess the response of the plate against the loading criteria and to ensure that the plate sustains the theoretically determined number of loading cycles. Findings The approach implemented provides a justifiable outcome for a weight-factor of safety trade-off. In addition to optimal material distribution, the generative design methodology provides several design outcomes, for different materials and fabrication techniques. This enables the selection of the best possible outcome for several structural requirements. Research limitations/implications This technique can be used for applications with pre-defined constraints, such as packaging and loading, usually observed in load-bearing components developed in the automotive and aerospace sectors of the manufacturing industry. Practical implications Using this technique can provide an alternative design solution to long periods spent in the design phase, because of its ability to generate several possible outcomes in just a fraction of time. Originality/value The proposed research provides a means of developing optimized designs and provides techniques in which the design developed and chosen can be structurally analyzed.

This study evaluates the distortion in an SLM-printed Ti-6Al-4V control arm plate of a double-wishbone suspension linkage. Temperature gradients are a common observation in selective laser melting (SLM). The development of residual stresses can lead to performance-based concerns due to the distortions emerging in part. Despite these shortcomings, SLM has often been employed in manufacturing high-end structural components under its ability to produce complex geometries. A thermomechanical simulation predicts the residual stresses developed in part and the distortions generated by those stresses. The simulation model is validated by reconstructing the printed part using computerized tomography (CT) and aligning it with the original design. The results reveal a close correlation between the predicted and the observed distortion, with the thickness of features and the location of support structures having a significant impact on postprint parts. Additionally, the study on build orientation helps understand the distribution of residual stresses and their redistribution after removing support structures.