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A collaboration between researchers from MIT, Carnegie Mellon University, and Lehigh University is set to transform the aerospace industry with a new design initiative funded by the Defense Advanced Research Projects Agency (DARPA). This project, part of DARPA’s Multiobjective Engineering and Testing of Alloy Structures (METALS) program, aims to develop advanced design tools that leverage artificial intelligence (AI) to optimize both the shape and material choices for complex aerospace components.
Traditional design methods often rely on a single material for entire components, which can lead to vulnerabilities in areas requiring different properties. For instance, in bladed disks (blisks) used in jet engines, varying temperatures and stresses necessitate a mix of high strength and resistance to creep or fatigue. Zachary Cordero, lead investigator and MIT Associate Professor, explains that existing design processes force engineers to find “one magical material,” resulting in inefficient compromises.
To tackle these limitations, the research team is focusing on “compositionally graded alloys,” which allow for a gradual change in material composition across a structure. This innovative approach enables specific properties to be tailored to different locations, enhancing performance and reliability. The researchers aim to harness advancements in additive manufacturing to achieve voxel-based control over material properties, paving the way for lightweight and durable aerospace components.
The implications of this research extend beyond aerospace, potentially driving innovation in various industries facing similar material challenges. By integrating machine learning, topology optimization, and generative modeling, the project seeks to develop AI-driven design tools that can simultaneously optimize both shape and material composition.
Cordero notes that this approach could lead to significant advancements in propulsion systems, making engines lighter and more efficient while improving durability. The collaboration between experts from different fields signifies a promising step towards revolutionizing engineering and materials science, with the potential to unlock new operational capabilities in previously inaccessible environments.
As this project progresses, it holds the promise of not only enhancing aerospace technologies but also inspiring a wave of innovation across diverse engineering disciplines.
