Supermaterials

Super materials are advanced, engineered materials designed to achieve performance beyond the limits of conventional systems—enabling stability in extreme temperatures, improved energy efficiency, and adaptive or multifunctional behavior. This work, funded by the U.S. Army DEVCOM Army Research Laboratory, focuses on understanding materials at the atomic scale using advanced neutron scattering, multimodal structural characterization, and AI-driven analysis. By resolving how atomic structure and disorder influence performance, researchers are enabling the intentional design of complex functional materials with tailored properties. These efforts are driving breakthroughs in extreme environment applications, energy conversion and storage, and next-generation structural systems critical to national defense.

This research is translated into scalable capability through advanced fiber-reinforced composites development and processing. Efforts span early-stage discovery through at-scale prototyping, with a focus on high-performance carbon fiber and carbon–carbon composites for extreme environments. Abilities include a wide range of advanced manufacturing processes such as compression molding, automated tape placement, braiding, filament winding, sheet molding compound, and additive manufacturing. Emphasis is placed on establishing fundamental structure–process–property relationships, supported by mechanical characterization, non-destructive evaluation, and machining. Recent work has demonstrated concept-to-prototype development of carbon–carbon composite structures, validated through field testing, while AI/ML integration is being applied to optimize materials and processing.

Complementing these efforts, research is advancing the understanding of carbon-based thermal protection materials under extreme aerothermal conditions relevant to hypersonic flight. Experimental campaigns using high-enthalpy plasma facilities—including an 80-kW plasma torch and a 500-kW pulsed arc-jet capable of Mach 6 conditions—enable detailed study of material ablation and gas–surface interactions. Novel in-situ diagnostics and controlled pre-heating techniques provide new insight into material response during exposure, generating critical data to improve modeling and inform the design of next-generation thermal protection systems. Together, these efforts represent a comprehensive approach to developing and deploying “super materials” for future operational environments.