Project Microstructure–Thermal–Mechanical Correlation for Feasibility Assessment of Recycled Thermoplastic Aerospace Composites Program DUIRI - Discovery Undergraduate Interdisciplinary Research Internship Term Summer 2026 Status Accepted Research Area Global Sustainability Description The increasing use of recycled thermoplastic materials in aerospace composite manufacturing reflects the growing need for reprocessable and adaptable structural systems. However, recycling processes can alter polymer microstructure through variability in material distribution, molecular weight reduction, and phase heterogeneity, which can influence load transfer, stress distribution, damage initiation, porosity formation, and dimensional stability under thermo-mechanical loading. While prior studies have compared the bulk mechanical properties of recycled thermoplastic composites, limited work has quantitatively linked measurable microstructural characteristics to composite-level structural reliability. This study develops a structured microstructure–thermal–mechanical correlation framework to evaluate the feasibility of recycled thermoplastic composites for aerospace applications. Microstructural characterization using imaging and thermal analysis will quantify morphology and variability introduced during recycling, while composite laminates will be fabricated under controlled processing conditions to isolate reprocessing effects. Mechanical performance will be evaluated through tensile and flexural testing before and after environmental exposure to assess strength and modulus retention. Thermal characterization using Differential Scanning Calorimetry (DSC), Thermogravimetric Analysis (TGA), and Dynamic Mechanical Analysis (DMA) will assess thermal stability and transition behavior. Supervisor Garam Kim Mentor Eduardo Barocio Vaca Type of work required Students will participate in the fabrication and characterization of recycled thermoplastic composite laminates. Responsibilities include specimen preparation, microstructural observation using microscopy, thermal characterization using Differential Scanning Calorimetry (DSC), Thermogravimetric Analysis (TGA), and Dynamic Mechanical Analysis (DMA), and mechanical testing including tensile and flexural experiments. Students will also assist with environmental conditioning of specimens and analyze experimental data to evaluate the relationship between microstructural characteristics, thermal behavior, and mechanical performance. This work provides hands-on experience in composite manufacturing, materials characterization, experimental testing, and engineering data analysis relevant to aerospace structural materials. Websites https://www.purdue.edu/cmsc/ Qualifications Applicants should have an interest in composite materials, aerospace structures, polymer engineering, or materials science. A basic understanding of mechanics of materials, polymer materials, or manufacturing processes is beneficial but not required. Students should be comfortable with hands-on laboratory work, able to follow experimental procedures carefully, and willing to participate in data analysis and interpretation. Familiarity with data analysis tools such as Excel, MATLAB, or Python is advantageous, along with strong motivation to learn composite manufacturing and materials testing techniques. Credit Hours 3 Weekly Hours 40 (estimated)