Successful development of a new high-performance composite material for the aviation industry

Within the framework of a State-level science and technology task under the Protocol between Viet Nam and the Republic of Austria, a research group from the Institute of Chemistry - VAST carried out the project “Research and development of high-performance epoxy-based polymer nanocomposite materials oriented towards aviation applications” (Code: NĐT/AT/22/22). The study aims to develop a new generation of composite materials with high durability, good impact resistance and greater stability during use.

Polymer nanocomposite material sample

To improve material quality, the research team simultaneously applied multiple solutions. First, the epoxy matrix - an engineering resin with high durability - was reinforced with nano-sized materials such as carbon nanotubes, making the material stiffer and more resistant to force. Next, the team used silane compounds capable of creating bonds between different material components for surface treatment, helping the material bond more tightly and limiting delamination under load. In addition, the surfaces of reinforcing fibre fabrics, especially aramid fibres - synthetic fibres with very high strength, light weight and toughness - were roughened to increase adhesion with the resin matrix. Another notable feature of the study is the design of hybrid materials by combining reinforcing fibres with different properties. Carbon fibre has high tensile strength and stiffness but poor impact resistance, while aramid fibre possesses good impact resistance.

Thanks to these solutions, the new material achieved notable parameters such as tensile strength of 534.18 MPa, flexural strength of 327.32 MPa, elastic modulus of 72.38 GPa and impact strength of 127.73 kJ/m². In particular, the material demonstrated dynamic fatigue resistance exceeding 10⁶ cycles at 70% tensile strength and still retained 96.25% of its properties after 52 ageing test cycles under ASTM G154 standards (technical standards used to test and evaluate materials). These results show that the material meets the demanding requirements of repeated loading and harsh environmental conditions in the aviation industry.

3D frame polymer composite material sample

Notably, the new material has a density of 1.523 g/cm³, significantly lower than metals commonly used in aircraft structures, helping reduce weight while maintaining the necessary durability. On that basis, the material has been experimentally applied in manufacturing the fuselage of the PELICAN VB01 unmanned aerial vehicle, weighing less than 2 kg while still meeting mechanical and physical requirements.

UAV fuselage sample – a technical achievement contributing to the implementation of Decision No. 1131/QĐ-TTg dated June 12, 2025 by the Prime Minister promulgating the List of Strategic Technologies and Strategic Technology Products

According to Associate Professor and Doctor Ngo Trinh Tung, the study demonstrates the capability to create high-performance composite materials domestically, meeting stringent requirements regarding durability, stability and light weight for aviation applications. This is clear evidence of the Institute’s scientists mastering advanced material technologies, opening opportunities to reduce dependence on imported sources and promote the development of high-tech sectors in Vietnam.

Associate Professor and Doctor Ngo Trinh Tung (far right) and Professor and Doctor Tung Pham (far left) together with research team members at the Institute of Physical Chemistry of Textiles, University of Innsbruck

Translated by Tuyet Nhung
Link to Vietnamese version