‘First of Its Kind’ Composite Material to Help Space Vessels Travel Longer Distances

A Coventry University design and materials engineer is leading an international team of researchers in the creation of a new material for liquid hydrogen storage tanks that are used to propel rockets into space.

December 1, 2024

Coventry University, Coventry, UK

Schematic illustrating the powder processing of the novel mixture and the production of the 2D-Grnp/AA 2195 MMC via the stir/squeeze casting process. (Image: Coventry University)

The future of space travel is seemingly changing by the day and a Coventry University academic is doing his bit to stay at the front of the space race.

Dr. Ashwath Pazhani along with an international team of researchers have created a new material for storing the liquid hydrogen used to propel rockets into space by the likes of NASA.

Their new material is lighter than the current material used for liquid hydrogen storage tanks and means that more fuel can be stored or more payload carried at one time – a feat that Dr. Pazhani describes as a “groundbreaking work that leapfrogs current research in the field”.

“This all started as I was looking for the super lightweight and load-bearing material for external fuel tanks. The material in question has been used since 1993 to store liquid hydrogen and yet in this work we innovatively reinforced this material with nano graphene, creating a new composite out of that,” said Dr. Pazhani, Lecturer in Engineering Design and Materials Specialism. “We have been able to reduce overall external tank weight by 2 percent, which is 19,400 kg of total weight reduction and that can be utilized towards sending 19 tons of extra payload in every space flight. This means space vessels can travel longer distances as well as carrying more payload. This is a significant innovation in liquid hydrogen storage and the material is the first of its kind. This achievement is groundbreaking in terms of sustainable energy solutions, aligning with global goals for cleaner and more efficient energy systems.”

Dr. Pazhani and his team of researchers detailed their development of the new material in a 19-page paper published in the Journal of Materials and Research Technology . The following section from the study gives an overview of their research.

The study presents a novel approach by integrating graphene with Aluminum alloy (AA) 2900 powder, synthesized through a high energy ball milling technique. The resulting powder was used to reinforce Aluminum alloy 2195, creating metal matrix composites (MMCs) via squeeze casting. The findings demonstrate that incorporating 0.5 wt percent 2D graphene nanoplatelets (2D-Grnp) in AA 2195 achieved density match, enabling homogeneous dispersion, addressing composite casting challenges. Consequently, the AA 2900 alloy embedded with 2D-Grnp facilitated the homogeneous dispersion of reinforcements during the squeeze casting process, yielding MMCs Ideal for potential use in lightweight liquid hydrogen fuel tank structures for launch vehicles. Following T8 heat treatment, the final casted composite plate exhibited significant enhancements in ultimate tensile strength, with a 4.5 percent increase over monolithic Al 2195-T8, exhibiting nominal reduction in elongation behavior and higher hardness. Additionally, scanning and transmission electron microscopy (SEM, TEM), Small Angle Neutron Scattering (SANS) and Electron Backscatter Diffraction (EBSD) revealed the squeeze casting technique’s effectiveness by exhibiting enhanced bonding among homogeneously reinforced 2D-Grnp, T1/θ’ precipitates, and AA 2195.

Dr. Pazhani hopes to see the material put to use soon and believes it could also be used in coming years for the sustainable storage of liquid and gaseous hydrogen in domestic household purposes, underground storage for fuel stations, and for transport systems including automotive, marine and aviation.

The research was carried out collaboratively with Professor Anthony Xavior from Vellore Institute of Technology in India, Dr. Andre Batako from Liverpool John Moores University, and Dr. Dirk Honecker at the Rutherford Appleton Laboratory.

As well as working with colleagues across the globe, Dr. Pazhani also used expertise closer to home in the form of a Coventry University student he once taught. Alicia Patel studied her master’s degree in aerospace engineering at Coventry University and was part of the materials testing team.

“In addition to its technical merits, it has also played an important role in promoting inclusivity and diversity in STEM, actively encouraging women to participate and lead in scientific breakthroughs,” said Dr. Pazhani. “Alicia’s contribution is a shining example of how student involvement can drive impactful research.”

This article was provided by the press team at Coventry University, it has been edited. For more information, contact This email address is being protected from spambots. You need JavaScript enabled to view it..