Recent advances in polymer nanocomposites for aerospace and space applications

Polymer nanocomposites are pervasive across several technological areas within the Air Force and Space Force and enable advanced capabilities in several applications. This presentation details recent advances in the design and characterization of high-performance polymer matrix composites and ceramic matrix composites that are enabled by a range of nanomaterials, including boron nitride nanotubes (BNNTs), carbon nanotubes (CNTs), MXenes and preceramic polymer grafted nanoparticles. Key applications explored include next-generation thermal and radiation shielding, particularly utilizing BNNTs, the development of self-healing capabilities in vitrimer-based polymers for extreme operational environments enabled by 2D materials such as MXenes and flexible and tough ceramics for extreme environments through polymer grafted nanoparticles. Predictive modeling is used to map the percolative 2D nanoparticle morphology to mechanical performance in vitrimer nanocomposites. Furthermore, the addition of nanoparticles, such as CNTs, leads to improved processibility and performance enhancements in additively manufactured composites. An example is the improved mechanical performance in thermoplastic composites via directional, nucleation-induced crystallization. The non-equilibrium structure and morphology of these nanocomposites are studied in real-time using advanced synchrotron X-ray scattering characterization methods with microbeam capabilities. This approach allows for detailed, in-situ mapping of nanoparticle alignment, defects, and structural heterogeneities during the AM process. Examining the in-process evolution of nanocomposites is one example that provides the fundamental understanding of the material’s microstructure required for selective tailoring to create unique properties, ensuring superior functionality and performance for applications essential for protecting humans and equipment across space exploration and defense systems.