Case studies: Materials engineer: Carlos

Carlos is a materials engineer. He did not study for a degree in materials but found himself attracted to this field of engineering whilst at university.

My interest in material science developed whilst studying for a degree in mechanical engineering. For my final year thesis, I undertook a materials-related project in which I had to select the best materials for the envelope on a radio-controlled airship, based on their strength and gas permeability.’ 

I now specialise in a particular field of materials – composites – and this has enabled me to pursue a career in a role that marries both materials and mechanical engineering expertise. I’m currently working as a materials engineer for a large aerospace organisation and have become an expert in the specific area of damage tolerance of composite materials. I now have a good understanding of the complexities of these new materials in comparison with traditional materials such as metals.

I think my decision to pursue materials within the field of aerospace has been a fortunate one. As a materials and mechanical engineer, it’s a really interesting time to be working in this sector. The introduction of composite materials to large aircraft components brings many challenges in both the manufacturing and assembly process. I’m currently working on three processes very specific to composite materials, namely non-destructive evaluation (NDE), repair, and shimming (i.e. tolerance gap management). NDE brings together the fields of physics (ultrasound waves, thermal behaviour, optical properties) and the material structure (internal flaws, delamination, fibre breakage, matrix cracks); Repair entails the creation of a whole new material to replace the damaged area.

I also think that the future holds even more challenges for materials scientists. I believe it will be our responsibility to industrialise and mass-produce high quality aerospace structures, at low cost, made of composite materials. New processes will have to be developed through lab-based research and then deployed into production and assembly lines. Materials engineers will play a vital role in developing organisations’ capabilities to deliver better and cheaper products. No small task but one that I’m enthusiastic to be involved in.