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Abstracts

“Sustained Self-healing in Structural Composites” by Dr. Jason Patrick (WP21-1240)

This presentation will describe the development of a novel self-healing composite platform for damaged FRP composites in advanced generation 5 and future aircraft structures and components based on thermally induced dynamic bond re-association of 3D-printed polymer interlayers. The technology delivers minute-scale healing over 1000+ cycles with 100% fracture recovery in both glass- and carbon-fiber composites. Unlike conventional approaches, this method enables self-repair in situ via resistive heating while maintaining structural integrity below the matrix’s glass-transition temperature. This latest self-healing advancement exhibits unprecedented potential for in-service repair along with material multi-functionality thereby engendering application versatility across DoD platforms.

“Aircraft Structural Repair of High Strength Aluminum Alloys by a Solid-State Additive Manufacturing Process” by Dr. J. Brian Jordon (WP21-1102)

This presentation will highlight the development of repair strategies based on Additive Friction Stir Deposition (AFSD), a solid-state additive manufacturing process, to restore damage and material loss due to galvanic corrosion in high-strength aluminum alloys. Operating below the melting point, AFSD enables defect-free, one-to-one material deposition while preserving the repaired component’s mechanical integrity. This presentation will elaborate on AFSD’s effectiveness through advancements in deposition methodology, bond quality characterization in repaired fastener holes, structural resilience, and mechanical performance under simulated operational conditions. These innovations reduce lifecycle costs and extend aircraft service life through field-deployable repair solutions.

Speaker Biographies

Dr. Jason Patrick is an Associate Professor in the Department of Civil, Construction, and Environmental Engineering with an affiliate appointment in Mechanical and Aerospace Engineering at North Carolina State University, Raleigh. He is an internationally recognized expert in developing bioinspired polymeric material systems that exhibit multi-functionality (e.g., self-healing) for enhanced performance, reliability, and longevity with more than 20 years of experience in research and development of advanced fiber-reinforced polymer composites. Dr. Patrick has served as a principal and co-principal investigator of projects funded by SERDP, the Air Force Office of Scientific Research, and the National Science Foundation. He is also the founding President and Chief Technology Officer of Structeryx, Inc. aimed at translating this next-generation composite technology to the DoD and industrial sectors. Dr. Patrick earned his doctoral degree in structural engineering from the University of Illinois Urbana-Champaign.

Dr. J. Brian Jordon is the Kenneth and Celia Carlile Endowed Chair in Materials Science and Professor in the Department of Mechanical Engineering at Baylor University’s School of Engineering and Computer Science, where he also serves as Associate Director of the Point-of-Need Innovations Center. Dr. Jordon’s research centers on advanced manufacturing and joining processes to develop materials with enhanced mechanical properties and tailored microstructures, with a particular focus on the relationship between microstructure and mechanical performance. Recognized among the top 2% of most-cited researchers globally, his work has been supported by the Department of Defense, Department of Energy, national laboratories, and industry partners. Prior to joining Baylor University, he served as a professor of mechanical engineering and a faculty member in the materials science program at the University of Alabama. Dr. Jordon earned his doctoral degree in mechanical engineering from Mississippi State University.