Careers and research at the intersection of statistical physics and aerospace composites

Conventional manufacturing of aerospace composites using autoclaves produces high quality parts but at a high cost, both in terms of time and energy. So-called agile manufacturing processes, such as additive manufacturing and liquid composite molding, are a class of promising techniques for increasing throughput, rapid prototyping, and achieving parts with intricate geometries and/or graded material properties. Designing these processes, however, is nontrivial as the underlying physics can include complexities such as multiphase and non-Newtonian fluid dynamics, heat transfer, and changes in material morphology due to the curing or crystallization of polymers (i.e. nonequilibrium thermodynamics). In this talk, we explore the modeling of these processes through the lenses of polymer and statistical physics. We aim to understand the interplay of processing parameters and phenomena such as wetting, polymer crystallization, electrorheological effects, etc., on aerospace part quality. By elucidating fundamental mechanisms that control processing-morphology-property relationships, we hope to inform the development and design of future agile manufacturing processes. In addition to fundamental research, this talk will give a perspective on careers in physics with alternatives to academia.