Team of Faculty and Students Collaborating with Leading European Institutions on 86th Parabolic Flight Campaign��

Khalifa University of Science and Technology proudly announces a historic milestone for the Gulf Cooperation Council (GCC) region, as a joint team from its Research & Innovation Center for Graphene and 2D Materials (RIC-2D) and the Khalifa University Space Technology and Innovation Lab (KUSTIL) becomes the first-ever GCC-based research group to collaborate with Université Libre de Bruxelles (ULB) to perform the experiments onboard the parabolic flight mission executed by the European Space Agency (ESA). The team is participating in ESA’s 86th Parabolic Flight Campaign, marking the first zero-gravity collaboration between European institutions and the GCC.  ��

The researchers’ team, which includes Khalifa University faculty and students, are testing graphene-enhanced materials for space applications in real zero-gravity conditions during the parabolic flight campaign. Dr Yarjan Abdul Samad, Assistant Professor, Aerospace Engineering, is leading the team of researchers from Khalifa University, which initially prepared the experimental setup at the Centre for Research and Engineering in Space Technologies (CREST) of the Université libre de Bruxelles (ULB), before traveling to Bordeaux, France. Dr. Abdul Samad and Professor Sean Swei along with researchers have visited CREST at ULB, under the directive of Dr. Carlo Iorio, to finalize the flight procedures and experimental requirements.  ��

The collaboration involved hands-on training in experiment setup and manipulation leading up to the scheduled flight campaign. CREST, is complementing with the necessary equipment and services for scientific collaboration and experiments.   ��

1. H.E. Homaid Al Shimmari, Vice-Chairman of the Board of Trustees, Khalifa University, said: “We are incredibly proud of this achievement and the recognition it brings to Khalifa University, the UAE, and the region. This pilot project not only showcases our commitment to advancing aerospace engineering but also ��ݮ��Ƶ the advancements made in graphene through the Research & Innovation Center for Graphene & 2D Materials. Moreover, this will enhance faculty and student exposure by providing a unique opportunity to test graphene-enhanced materials for space applications. This initiative represents a significant step forward in our collaboration with international space agencies, global academic institutions and demonstrates the potential of such materials in space exploration.” 

2. Dr. Carlo Iorio, Co-Director at the Centre for Research and Engineering in Space Technology, Université libre de Bruxelles, said: “This parabolic flight campaign represents an important step for strengthening the collaboration between our Institute, Khalifa University, and the Research & Innovation Center for Graphene & 2D Materials. I am especially happy to motivate the young researchers involved in this campaign towards higher objectives and success. For them and the others that will come as part of this collaboration, the sky will no longer be the limit!” ��

As part of its regular parabolic flight campaigns, the European Space Agency is responsible for flying experiments and the on-ground support. The outcomes of this project are expected to result in publications that will contribute to the scientific community. The project focuses on laser-propelled graphene produced at Khalifa University, from the Pilot Manufacturing joint project titled, Photonic Propulsion of Innovative Graphene-Based Space Material. The researchers will participate in the experiment that will lead to gathering of crucial experimental data. ��

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Creativity, Design, and Rapid Manufacturing Made ‘Raven’ Structurally Advanced Aircraft����

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Khalifa University’s student-built ‘Raven’ aircraft made an impressive display during the 29th Annual American Institute of Aeronautics and Astronautics (AIAA) Design/Build/Fly (DBF) Competition, the most prestigious international competition for building and flying remote-controlled aircraft that was held in Tucson, Arizona, US.��

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Team ‘AERONYX’, comprising 36 Aerospace Engineering students and guided by Dr. Rafic Ajaj, Associate Professor, and co-supervised by Dr. Ashraf Alkhateeb, Assistant Professor, and Professor Yahya Zweiri, Director, Advanced Research and Innovation Center (ARIC), designed and built the ‘Raven’, a structurally advanced, remote-controlled aircraft. This year’s DBF challenge required teams to develop an unmanned, electric-powered aircraft with a focus on structural performance and mission efficiency. The team proudly secured 36th place out of 112 teams.��

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The flight objective for AIAA DBF 2025 held from 10 -13 April, was to design, build, and test an airplane to execute an X-1 Supersonic Flight Test Program, including the launch of an X-1 test vehicle – an autonomous glider with flashing lights. Teams also conducted a timed ground mission demonstration of the X-1 Flight Test Program. The goal was to possess a balanced design, good demonstrated flight handling qualities, and practical and affordable manufacturing requirements, while providing a high vehicle performance.����

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Led by student Hamad Almaeeni, the team optimized Raven for coordination, performance, and mission success. Avionics lead Alyazia Al Khemeiri installed the electronics and selected and tested the propulsion system to deliver high thrust with great efficiency, enabling Raven to complete five laps and launch the X-1 test vehicle into the bonus zone. The aircraft’s lightweight and robust frame was designed and built by Rashid Althli, Sultan Alhammadi, and Shooq Alkaf. Mohamed Elmubarak and Saeed Al Marzooqi co-designed the X-1 deployable aircraft, which performed a 180-degree maneuver and a controlled spiraling descent, landing in a designated area with flashlights that are activated immediately upon deployment. The pilot’s precision during critical flight operations was vital to the execution of Missions 2 and 3. The team’s participation was sponsored by Mubadala Investment Company.��

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Dr. Ajaj (Associate Professor of Aerospace Engineering) said: “Khalifa University’s Raven successfully completed the ground mission as well as all three flight missions. The strategic combination of creativity, design, and rapid manufacturing gave Raven a competitive edge and few other teams managed to deliver such structurally advanced aircraft while maintaining low weight. Also notable this year was the use of 3D-printed components, a creative and resourceful approach by the Khalifa University team. Our students’ efforts were truly commendable.”

Clarence Michael
English Editor – Specialist��

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Project Recognized for Engineering Excellence and Relevance to Sustainable Air Transportation��

Khalifa University has clinched the gold medal in the University Projects Category at the International Radio-Controlled Aerobatic Competition in Al Ain, UAE. The winning project, titled ‘Hybrid-Electric Propulsion System for VTOL Drones and Sustainable Air Mobility,’ was developed by the Aerospace Systems Group and is part of the University’s flagship FALCON Program, aimed at advancing sustainable aviation technologies.��

Led by Principal Investigator Professor Roberto Sabatini, with contributions from Dr. Alessandro Gardi, Dr. Nour El-Din Safwat, and Ahmed Elmeligy, the project represents a major leap in hybrid aerospace engineering. This success was celebrated by Khalifa University President H.E. Professor Ebrahim Al Hajri, who also attended the competition.��

The innovation integrates a puller electric motor with a pusher internal combustion engine, powered by renewable energy sources including solar panels and hydrogen fuel cells. The system addresses critical challenges in VTOL drone operations such as limited range and environmental impact, offering a scalable, adaptable solution for the future of urban and regional air mobility.��

The research team also developed real-time software and hardware infrastructure for propulsion and power management, optimizing energy use and performance. The project was recognized not only for its engineering excellence but for its real-world relevance to sustainable air transportation.��

Team NOVAERO from Khalifa University secured second place for their ZENITH project, while another student achieved third place in the Flight Simulator Category, demonstrating Khalifa University’s depth of talent in aerospace research.��

Khalifa University continues to advance sustainable aviation through ongoing projects such as the ‘Intelligent Power and Mission Management System for Hybrid-Electric Air Mobility’, under the Research and Innovation Grant (RIG-2024-030). This initiative focuses on using AI-based avionics to further enhance energy efficiency and propulsion systems.��

Professor Sabatini said: “By addressing critical challenges such as limited operational range and environmental impact, this sophisticated propulsion system paves the way for next-generation solutions in sustainable air mobility. The tremendous talent and innovation showcased by our students with the first and second place wins by the FALCON and ZENITH projects, along with the impressive third-place finish in the Flight Simulator Category, are testament to the hard work and dedication of our students and faculty.”��

Alisha Roy
Science Writer��

The post Khalifa University Wins Gold in Al Ain International Radio-Controlled Aerobatic Competition�� appeared first on Khalifa University.

Appointment Highlights Prof. Roberto Sabatini’s Contributions to Aerospace Systems Research, Innovation, and Education������

Khalifa University faculty Prof. Roberto Sabatini, Department of Aerospace Engineering has been elected as Vice-President of Technical Operations by the IEEE Aerospace and Electronic Systems Society (AESS), the most prestigious professional organization entirely dedicated to this field.��

This appointment ��ݮ��Ƶ Prof. Sabatini’s extensive contributions to aerospace systems research, innovation and education, over the past three decades. His career is marked by a series of leadership roles across industry, government, and academia in Europe, North America, Australia, Asia, and the Middle East, making him a renowned figure in the advancement of aerospace and aviation technologies worldwide.��

Prof. Sabaini’s research addresses key contemporary challenges in avionics, spaceflight and robotics/autonomous systems design, test and certification, focusing on the central role played by cyber-physical systems and AI in the digital transformation and sustainable development of the aerospace and aviation sectors. Practical applications include trusted autonomous flight systems, urban and regional air mobility, distributed space systems, space domain awareness, and multi-domain traffic management.����

Throughout his career, Prof. Sabatini has led several industry and government-funded research projects and has authored or co-authored more than 350 peer-reviewed international publications. He holds various academic qualifications in engineering, science and management disciplines, including doctoral degrees in Aerospace Engineering (Cranfield) and Geospatial Systems (Nottingham).����

As a licensed Flight Test Engineer, Private Pilot and Remote Pilot, he has logged more than two thousand flight hours on various aircraft types, including jets, turboprops, propeller aircraft, helicopters, and both fixed-wing and multi-rotor unmanned aircraft. Prof. Sabatini is a Chartered Professional Engineer (CPEng), as well as a Fellow and Engineering Executive of Institution of Engineers Australia (FIEAust and EngExec). He is also a Fellow of the Royal Aeronautical Society (FRAeS), Fellow of the Royal Institute of Navigation (FRIN), and Fellow the International Engineering and Technology Institute (FIETI).��

Currently, Prof. Sabatini serves in the editorial board of several journals, including the IEEE Transactions on Aerospace and Electronic Systems, Progress in Aerospace Sciences, Robotica, Aerospace Science and Technology, the Journal of Navigation, and the IEEE Aerospace and Electronic Systems Magazine.��

Since joining Khalifa University in 2021, Prof. Sabatini has founded the Intelligent and Autonomous Aerospace Systems (IAAS) Group and the Guidance, Navigation and Control Laboratory (GNC-Lab). He also leads the FALCON program, a transdisciplinary research and training initiative dedicated to the future of aviation and commercial spaceflight. The FALCON program addresses critical gaps in sustainable flight systems design and operations, including advanced air mobility, high-speed and suborbital transport, and the seamless integration of ground and space-based communication, navigation and surveillance infrastructure.��

Prof. Sabatini said: “As Vice-President Technical Operations of the IEEE AESS, I envision a future where the aerospace and electronic systems community capitalizes on its strengths, embraces constant improvement, and leverages collaboration opportunities to maximize impact. I am strongly committed to the AESS mission and values, and I have actively contributed to this prestigious society since 2008 in various technical and operational leadership roles. As Vice-President, I will continue working with the team to uphold the highest possible standards in technical operations, also contributing to high-impact publications, educational initiatives, conferences, and standardization working groups.”��

Alisha Roy

Science Writer

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Third Consecutive Award Reflects Research Caliber of Aerospace Engineering Department and FALCON Program

Khalifa University’s Intelligent and Autonomous Aerospace Systems Group has won the Outstanding Research Paper Award in the Space Situational Awareness session at the Space Research Conference (SRC) 2024. This first-of-its-kind event was organized by the UAE Space Agency in Abu Dhabi as part of the World Space Week activities.��

The award-winning paper titled ‘Hybrid Sensor Networks: Space Debris Tracking through Intelligent Distributed Space Systems and Ground-Based Observations’ tackles the critical issue of orbital congestion caused by Resident Space Objects (RSOs).�� The research team working on this project is led by Professor Roberto Sabatini and includes PhD student Khaja Faisal Hussain, Dr. Kathiravan Thangavel, Dr. Noureldin Safwat, and Assistant Professor Alessandro Gardi, form the Department of Aerospace Engineering. The award-winning paper will be featured on the UAE Space Agency’s Space Research Platform.����

The Intelligent and Autonomous Aerospace Systems Group is a key component of Khalifa University’s Flight Systems Research and Training (FALCON) Program, which addresses key contemporary challenges in sustainable flight systems design and operations, including advanced air mobility, high-speed and suborbital transport, and the integration of ground and space-based Communication, Navigation and Surveillance (CNS) infrastructure. It is led by Prof. Sabatini, who also serves as at the .����

The paper introduces an innovative multi-sensor data fusion strategy that combines intelligent Distributed Space Systems (iDSS) with ground-based sensor capabilities to achieve real-time tracking of space debris, significantly enhancing Space Situational Awareness (SSA) and promoting safer, more sustainable orbital and suborbital flight.��

Prof. Roberto Sabatini said: “Receiving three awards in a two-week timespan was amazing and the team deserves to be commended for this incredible series of achievements. After receiving two awards in the US at the AIAA/IEEE Digital Avionics Systems Conference both in the Digital Flight and Space Systems sessions, this additional recognition at the UAE Space Research Conference underscores the importance of aligning our research with the aerospace sector’s national and international priorities.”��

In addition to their award-winning research, the Group made significant contributions to two other conference tracks: Satellite Communication (SatCom) and Earth Observation. In the SatCom track, they presented a paper titled ‘Robust Communication in Remote Regions: An Integrated Satellite-HAPS-5G Architecture for Traffic Routing in Adverse Weather Conditions.’ This research aims to provide robust communication solutions in remote and underserved regions, especially during adverse weather conditions, by developing dynamic traffic routing algorithms that adapt to environmental changes.��

In the Earth Observation track, the team presented ‘Distributed Satellite Systems for Enhanced Earth Observation: Applications in Climate Change Monitoring and Disaster Management.’ This paper ��ݮ��Ƶ the use of Distributed Satellite Systems (DSatS) to tackle global challenges like climate change and natural disasters. The research underscores the role of DSatS in providing high-resolution, timely data for proactive disaster management and climate change analysis, contributing to the United Nations Sustainable Development Goals (SDGs).��

A flagship project within the FALCON program is the development of a Multi-Domain Traffic Management (MDTM) framework, conducted in collaboration with leading industry and government partners. This project aims to ensure the safety, efficiency, and sustainability of integrated air and space transport operations, paving the way for a more connected, efficient, and environmentally responsible future in the aerospace sector and beyond.

By addressing the challenges of modern air and space transport, the program contributes to the advancement of the UAE’s aerospace industry and sets a global benchmark for sustainable innovation in flight systems design and operations.��

Alisha Roy��

Science Writer

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Khalifa University’s Dr. Elena Fantino Will Transition to Become Chair after her Current Three-Year Role as Vice-Chair

Khalifa University faculty Dr. Elena Fantino, Associate Professor Aerospace Engineering, was unanimously elected as Vice-Chair of the Astrodynamics Technical Committee of the International Astronautical Federation (IAF).����

Effective from 19�� October 2024, Dr. Fantino’s appointment for three years was announced during the recent International Astronautical Congress held recently in Milan, Italy. Following her term, she will transition to the role of Chair, taking on an even greater leadership responsibility for another three years.��

The Astrodynamics Technical Committee is comprised of 32 global experts and plays a crucial role in advancing research and innovation in astrodynamics, a field critical to the future of space exploration. Dr. Fantino will help guide the committee’s strategic direction.����

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“It is a great honor for me,” Dr. Fantino said. “I am particularly proud that through this election, Khalifa University assumes a leading role in one of the most prestigious international institutions of my field.”��

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Founded in 1951, the International Astronautical Federation is the world’s leading advocacy body with more than 500 members in 77 countries, including all leading space agencies, industries, research institutions, universities, societies, associations, institutes and museums worldwide.����

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The Astrodynamics Technical Committee has the mandate of promoting advances in orbital mechanics, attitude dynamics, guidance, navigation and control of single or multi-spacecraft systems as well as space robotics.��

Jade Sterling

Science Writer

25 October 2024

The post Faculty Elected Vice-Chair of IAF’s International Astrodynamics Committee appeared first on Khalifa University.

‘Best of Session’ Awards in Space Systems and Digital Flight Rules Reflect Impactful Innovations in Advanced Air Mobility and Spaceflight

Khalifa University’s Intelligent and Autonomous Aerospace Systems Group (FALCON Program) has won two ‘Best of Session’ awards, at the AIAA/IEEE 43rd Digital Avionics Systems Conference (DASC) 2024, held in San Diego, US. The event is one of the most prestigious and longest running international annual gatherings of industry leaders, professionals, and experts in avionics systems for atmospheric and space flight.

The two awards for the Space Systems and Digital Flight Rules sessions highlight the university’s commitment to address key contemporary challenges in Advanced Air Mobility (AAM) and Space Domain Awareness (SDA), areas that are crucial for the future of aviation and spaceflight operations.

The paper at the Space Systems session titled ‘Resident Space Objects Tracking Using Estimation-Based Data Fusion’ addresses the important challenge of orbital congestion due to the increasing number of Resident Space Objects (RSOs). It proposes a Space-Based Space Surveillance (SBSS) system designed to enhance the tracking of RSOs and support the evolution of SDA into an effective Space Traffic Management (STM) framework. This is key to mitigating the risks associated with the Kessler syndrome, a scenario where the density of objects in Low Earth orbit (LEO) is high enough to cause collisions that generate more debris, while ensuring satellite operations remain safe and efficient.

The paper at the Digital Flight Rules sessions on ‘Intelligent Cyber-Physical System for Advanced Air Mobility and UAS Traffic Management’ focuses on integrating conventional Air Traffic Management (ATM) with Unmanned Aircraft Systems Traffic Management (UTM) to ensure the safe and efficient operation of increasingly automated and autonomous flight vehicles. It discusses the integration of ATM, UTM/AAM, and Space Traffic Management (STM) into a cohesive Multi-Domain Traffic Management (MDTM) system, crucial for managing the complexities includes an expansion of both low-altitude and high-altitude operations.

The FALCON program is led by Dr. Roberto Sabatini, Professor of Aerospace Engineering and Vice President of Technical Operations at the . With several industrial and academic partners across five continents, the FALCON program aims to establish a transdisciplinary research and training center devoted to future aviation and spaceflight systems.

This initiative focuses on highly automated and autonomous flight vehicles, ground-based infrastructure, and decision support systems for the optimal management of airspace, traffic flows, and missions. Key contributors to the DASC 2024 award-winning articles were PhD student Khaja Faisal Hussain, Post-Doctoral Fellows��Dr. Nour Eldin Safwat��and��Dr. Kathirvan Thangavel, and��Dr. Alessandro Gardi, Assistant Professor, from the Department of Aerospace Engineering.

Professor Sabatini said: “Our success at DASC 2024 is a testament to the hard work and innovative spirit of our research group. By addressing critical challenges in advanced air mobility and space domain awareness, we are not only contributing to the advancement of aerospace technology but also paving the way for safer, more efficient, and sustainable management of airspace resources. Khalifa University’s innovative work on MDTM systems, coupled with thorough preparation and strong alignment with industry needs, led to these significant recognitions. I am very proud of our team’s achievements and their commitment to excellence in research and innovation.”

Clarence Michael
English Editor Specialist
15 October 2024

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Professor Yahya Zweiri’s Patent Additionally Covers Methods for Operating Vehicle in Multiple Environments

A hybrid vehicle technology developed by Khalifa University professor Dr. Yahya Zweiri, Director, Advanced Research and Innovation Center (ARIC), has secured a patent for the Hybrid Unmanned Aerial and Submersible Vehicle (UASV) representing a significant advancement in multifunctional autonomous vehicles.

Capable of operating as an aerial drone, water surface vehicle, and an underwater submersible, this platform addresses a wide range of applications, including environmental monitoring and search and rescue operations.

The UASV, described in the patent ‘US 12,037,095 B2’ is capable of seamlessly transitioning between air, water, and underwater operations. A fuselage, wing structures, a propulsion system, and a tail assembly allow the vehicle to adapt to different environments.

Professor Yahya Zweiri said: “The development of this hybrid vehicle showcases Khalifa University’s commitment to pushing the boundaries of aerospace engineering and innovation. Receiving the US patent ��ݮ��Ƶ the potential impact on various industries and applications and demonstrates the university’s enterprising approach to research and development.”

The patented UASV technology developed by Professor Zweiri at Khalifa University has far-reaching implications for fields such as environmental monitoring, search and rescue, and security applications, to monitor missions from a safe location, eliminating risks to personnel, and reducing cost.

A unique wing tilting mechanism, which allows the wings to rotate 360 degrees enables the vehicle to adjust its configuration for optimal performance and a smooth transition between aerial, surface, and underwater modes. The tilting wings also allow the UASV to take off and land on water or any surface without the need for a runway, providing a fast and seamless air-to-water transition.

The UASV also features a propeller protection system, a landing system, control surfaces, and an array of sensors to enhance its versatility and safety.

Alisha Roy
Science Writer
4 Sep 2024

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Carbon Fiber Reinforced Elastic Skin Maintains Rigidity in Lab Flight Tests����

Researchers from Khalifa University have engineered a novel carbon fiber-reinforced elastomeric material for airplane wings, advancing morphing wing technologies in the aerospace industry. By combining carbon fiber with a specially designed elastic material, the team created a skin that can stretch up to 200% without getting thinner, offering potential improvements in efficiency, maneuverability, and overall aircraft performance.��

The study was published in a paper titled ‘Innovative Skin Structures: Synthesis, Void Analysis, and Hysteresis Modeling of Zero Poisson’s Ratio Skin for Span Morphing Wing’ in the International Journal of Applied Mechanics (IJAM). The co-authors include Dr. Dilshad Ahmad, Postdoctoral Fellow, Advanced Research and Innovation Center (ARIC), Department of Aerospace Engineering, Khalifa University, Sankalp Gour and Deepak Kumar from the Department of Mechanical Engineering at Maulana Azad National Institute of Technology, Bhopal, India, as well as Dr. Rafic M. Ajaj, Associate Professor, Aerospace Engineering, Khalifa University, and Dr. Yahya Zweiri, Director, ARIC.��

The study focuses on the development of advanced elastomer-based viscoelastic skin structures with a zero Poisson’s ratio, aiming to enhance efficiency and adaptability in aerospace engineering. The primary advantage of a zero Poisson’s ratio skin is its ability to allow significant longitudinal stretching (up to 200%) without getting thinner, unlike most materials that shrink when stretched. By reducing the Poisson’s ratio, the new material can be used for airplane wings that need to change shape during flight, as well as for soft robotics and other high-tech applications.��

The research involved advanced imaging techniques such as the Micro-CT tomography and X-ray tomography to confirm that the material combined with carbon fiber has the ability to stretch in one direction without changing its shape. Double degassing process, both before and after the insertion of the carbon fiber, in removing any trapped air bubbles ensured the creation of the high-quality elastomeric morphing skin.

The study also created an Unmanned Ariel Vehicle (UAV) wing that can double its wingspan with wind tunnel tests at various speeds and angles showing the skin bent less than 0.5 mm. Another part of the study found that using a special lightweight material could boost the wing’s lift by up to 21%.

Alisha Roy
Science Writer
12 July 2024

The post Morphing Airplane Wing Material Can Boost Flight Efficiency appeared first on Khalifa University.

Professor Rehan Umer Awarded the Prestigious Distinction for His Achievements in Aerospace Engineering Leadership and Research��

Khalifa University’s Dr. Rehan Umer, Professor, Aerospace Engineering, is elected as Fellow of the Royal Aeronautical Society (FRAeS), for his contributions to advancing the aerospace engineering sector.

The current Fellows of the Society elected Dr. Umer for this rare honor, which is granted to only those in the profession of aeronautics or aerospace, who have made outstanding contributions in the field, or have attained a position of high responsibility in an aerospace-related profession.��

Dr. Umer’s appointment comes as a result of his exceptional contributions to the aerospace community as well as his expertise and research acumen, earning him widespread recognition in the field. As a prolific author, Dr. Umer has published three books, numerous refereed journal articles, and conference papers, showcasing his extensive understanding of aerospace engineering and his commitment to advancing the discipline.

Beyond academia, Dr. Umer holds four US patents and has played a pivotal role in establishing collaborative research centers by co-founding the Advanced (Aerospace) Research and Innovation Center (ARIC), a joint venture between Khalifa University and STRATA Manufacturing. As the founder of the Composites Manufacturing Lab, he also spearheads groundbreaking research on process modeling and simulations, the additive manufacturing of lightweight composite structures, machine learning and augmented reality of advanced manufacturing in Industry 4.0.

Moreover, Dr. Umer’s research contributions extend beyond his current affiliations through his active involvement in Khalifa University’s Research and Innovation Center on Graphene and 2D Materials (RIC-2D), which is hosted by Khalifa University as part of a strategic investment by the Government of Abu Dhabi to advance the scientific development and commercial deployment of technologies derived from graphene and other 2D materials. As a theme and project lead, Dr. Umer is instrumental in driving advancements in the utilization of graphene and 2D materials within the aerospace industry.

One of Dr. Umer’s notable research endeavors involved a collaborative effort between Khalifa University and STRATA Manufacturing, investigating the deformation of aerospace parts during the manufacturing process. Through the use of advanced simulation tools, Dr. Umer and a research team developed predictive models that enable manufacturers to anticipate and mitigate deformations, ensuring the production of high-quality aerospace components. Furthermore, he has contributed to the development of an innovative approach to model the behavior of woven fabrics under stress cycles. This breakthrough research facilitates the selection of optimal materials for aircraft components, enhancing their performance and safety.

Dr. Rehan Umer said: “I am delighted to receive this prestigious and rare honor, joining the ranks and becoming one of the Fellows of the Royal Aeronautical Society, the highest grade attainable for professionals in the field of aeronautics or aerospace. I would like to thank Khalifa University for its generous support for all the research over the years as well as the Society’s commitment to upholding professional standards and fostering a central forum for knowledge sharing, which is truly commendable.”

With more than 25,000 members representing over 100 countries, the Royal Aeronautical Society, established in 1866 to further the art, science and engineering for aeronautics, is the only professional body dedicated to aerospace, aviation and space communities.

Alisha Roy
Science Writer
17 April 2024

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A team of researchers from Khalifa University has developed an approach to model the behavior of woven fabrics under stress cycles. Modeling this allows manufacturers of aircraft components to choose the most appropriate materials.

The aerospace industry is continuously searching for materials that are lightweight but strong enough to resist the stresses and strains of flight. Advanced composite materials including 3D orthogonally woven fabrics (fibers woven at right angles) offer many unique features and benefits over other materials, but before they can be used, they need to be tested.

A team of researchers from Khalifa University has developed an approach to model the behavior of fiber-reinforced polymer composite (FRPC) fabrics under stress cycles. Woven fabrics will compress and relax in a particular way that depends on the architecture and properties of the fabric reinforcement used in the manufacturing process. Modeling this allows manufacturers of aircraft components to choose the most appropriate materials.

The team included Siddhesh Kulkarni, Masters Student; Dr. Rehan Umer, Associate Professor; Prof. Wesley Cantwell, Aerospace Engineering; Khalid Alhammadi, Undergraduate Student; and Dr. Kamran Khan, Associate Professor. Their results were published in.

A composite material is a combination of materials designed to achieve specific structural or performance properties. FRPCs are one such type of composite used in aerospace applications. They are manufactured using liquid composite molding (LCM) processes, where a dry fabric reinforcement is kept between two molds and then compacted to a target thickness while a liquid resin is injected into the fabric.

FRPCs can enhance structural performance in an aircraft while reducing weight. Their high strength, load-bearing capability, high corrosion resistance, and enhanced durability makes FRPCs state-of-the-art materials in aerospace applications.

Fibers in such composites can be woven in either two or three dimensions, with 3D fabrics preferred for critical structural components, such as engine fan blades, as they offer higher stiffness and out-of-plane strength.

“Woven fabrics exhibit a viscoelastic response that depends on the fiber reinforcement,” Dr. Khan said. “This means that the fabric’s stress response will depend not only on the deformation, but also on the rate of deformation during compaction.

Furthermore, when the fabric is held at a constant thickness after compaction, it exhibits relaxation of stresses. Therefore, the rate-dependent viscoelastic compaction response also needs to be considered when modeling the fabric’s behavior under various stresses.”

The compaction behavior of fabric reinforcements demonstrates a unique, non-linear stress-deformation response curve. Using this knowledge, the team experimentally investigated the rate-dependent response of a 3D orthogonal woven fabric under different loads and developed a model to understand how the fabric would respond. Their model could also predict the fabric’s response to stress until the cycles of compaction and relaxation caused microstructural changes, which the team found became extensive after four rounds of testing.

“This work is a continuation of a project that focused on introducing 3D reinforcements in Aerospace composites such as the fan blade of an aircraft engine,” Dr. Khan said. “There are issues related to processing thick 3D preforms to achieve high fiber content and better resin permeability. The modeling work helps to predict mold clamping forces hence identifying strategies to inject resin in an LCM mold.”

Jade Sterling
Science Writer
14 March 2023

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A team of researchers from Khalifa University and STRATA has investigated the ways in which parts manufactured for the aerospace industry may deform during the manufacturing process using simulation tools to predict these deformations before they happen.��

PhD student Mariam Ahmed Al-Dhaheri, Dr. Kamran Khan, Associate Professor of Aerospace Engineering, Dr. Rehan Umer, Associate Professor of Aerospace Engineering, and Prof. Wesley Cantwell, Director of the Advanced Research and Innovation Center (ARIC) and Associate Dean for Research, with Frank van Liempt, STRATA Manufacturing, reached accurate results in predicting the process-induced deformations of composite sandwich structures, with less than five percent error. Their research was funded by Mubadala Aerospace and published in.

A composite material combines various material ingredients to achieve specific structural properties. Polymer-matrix composite (PMC) materials are one such example used in aerospace applications.

PMC materials can enhance performance in an aircraft while reducing weight. Their high strength, stiffness, and toughness combined with low density make them the structural material of choice for aircraft components.

“The use of high-performance polymer-matrix composite materials in the aerospace industry has increased significantly in recent years, due largely to their high strength-to-weight ratio, immunity to corrosion, and excellent fatigue resistance,” Al-Dhaheri said. “They were first used in secondary structures, but more than half of the recent Airbus A350 is made from PMCs, and the Boeing B787 uses PMCs in the nose structure.”

However, PMCs are not immune to faults. One major issue is the potential for process-induced deformations (PIDs) that come from the manufacturing process itself, without any contribution from external factors. In aerospace manufacturing, these PIDs represent a significant concern during the design phase as they can cause difficulties during the final assembly.

“Aerospace composite structures are typically cured in an autoclave at high temperatures and pressures, involving a complex thermochemical cycle that cures the polymer matrix until it reaches a solid state yielding the required mechanical properties,” Al-Dhaheri said. “Although the curing process strengthens the composite structure, it also introduces residual stresses that remain in the structure upon cooling.”

When these parts are removed from the machinery that makes them, the material ‘relaxes’ as it is removed from its strained condition on the tool. This can cause structural deformation. Parts that aren’t quite right will be challenging to assemble, forcing aircraft technicians to apply greater levels of force to make them fit, which could create internal stresses or even damage the overall structure. The parts may even be deemed unsuitable and fail the airworthiness tests.

“Process-induced deformation is one of the main concerns during the manufacturing process of composite aerostructures,” Al-Dhaheri explained. “This is because residual stresses in the manufactured parts cause instability. Ultimately, this could lead to the part being rejected by the customer or even an expensive part being completely scrapped. Predicting these deformations numerically in the early design stages can help ensure conformity with the design and quality requirements.”

PIDs can be compensated for by accounting for these deformations during the design stage, but this is a trial and error approach, which is expensive and inefficient. Alternatively, process modeling or computer simulation approaches can streamline the production process.

“PIDs can be minimized by controlling specific parameters that contribute to the development of residual stresses,” Al-Dhaheri said. “Previous research has studied the effects of these parameters on process-induced deformations, but they haven’t considered composite sandwich structures, mainly the warpage in flat panels and the spring-in of curved structures, which is what our research focused on.”

Residual stresses are the internal stresses that develop during composite part processing. During curing, the materials undergo shrinking, and when cured into curved shapes, the angle between the two curved sides is reduced. This change in the angle is known as ‘spring-in’. Spring-in causes considerable difficulty and expense for composite manufacturers as it can vary with material, cure temperature, structure, and other manufacturing factors. This means that what worked once may not necessarily work the next time. If spring-in from residual stresses could be consistently and easily predicted, the manufacturing process could be tuned for specific part characteristics.

A large proportion of current aerospace composite components are light sandwich structures, where thin composite laminates constitute the ‘bread’, and honeycomb cell walls make up the ‘sandwich filling’. While light and strong, these structures are susceptible to damage and repairing them can be complicated. To date, there is little research into PIDs in sandwich structures, which the KU research team sought to rectify.

They used a simulation tool that can predict the occurrence of process-induced deformations in sandwich structures with a high degree of accuracy. They constructed a 3D finite element model of the composite part and simulates the curing process, as well as the interactions between the manufacturing tool and the part. From their simulations, the research team recommended that an aluminum core and aluminum tools should be used for manufacturing curved structures with reduced PIDs. They also recommended the sandwich design configuration to avoid large deformations in the final cured composite structure, compared to other designs.

While further experimental studies are needed to further validate the simulation findings, this represents a crucial tool to understanding the effects of various parameters on PIDs and improving the design and production process of airworthy composite parts.

Jade Sterling
Science Writer
14 November 2022

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