Advanced Materials & Manufacturing for Modernization- Project 9

Abstract The University of Kentucky (UK) and the Army Research Lab (ARL) have developed a collaborative fundamental research program, focused on the development of advanced materials and manufacturing processes to support U.S. Army modernization efforts. The scope of this research program impacts several critical technological domains, including hypersonics and other extreme environment applications, multi-scale additive manufacturing (AM) with an emphasis on large-area and point-of-need manufacturing, and novel materials development. While the proposed research is aimed at significantly advancing fundamental knowledge in these technological domains, technology transition frameworks have been established to ensure viable pathways towards eventual commercialization and application of gained insights by the U.S. Army and its industrial supply chain base. The proposed framework of this research program encompasses three research thrusts: (a) Multi-Scale AM for Extreme and Expeditionary Environments (b) Materials for Extreme Environments (c) Modeling and Characterization for Extreme Environment Applications To advance these initiatives, the UK has established a world-class research facility for cutting- edge additive manufacturing: The Next Generation Additive Manufacturing Research Laboratory (NextGen AMRL). This facility supports multi-scale AM capabilities ranging from micro-scale to ultra-large-scale, and it integrates a diverse array of deposition modalities—including fusion- based and solid-state—tailored to those length scales. By consolidating these technologies, NextGen AMRL provides a critical infrastructure for pushing the frontiers of fundamental AM research. A central objective is to elucidate and quantify the underlying process physics governing additive manufacturing for U.S. Army-relevant material systems and applications. This is achieved through comprehensive Process–Structure–Property (PSP) mapping, offering deep insights into how processing parameters influence the evolution of key microstructural features and mechanical performance. Technologies which will be leveraged include Additive Friction Stir Deposition (AFSD), Cold Spray Additive Manufacturing (CSAM), Directed Energy Deposition (DED), Aerosol Jet Printing (AJP), and Powder Bed Fusion (PBF). Research in the materials and applications extreme environment thrusts will focus on the development of novel materials systems for DoD applications. Furthermore, a primary focus will be advancing computational and experimental methodologies for high-temperature materials and thermal protection systems (TPS). Key initiatives include modeling and validation efforts for the new Inductively Coupled Plasma (ICP) facility, developing an Integrated Computational Materials Engineering (ICME) framework, and enhancing predictive capabilities for damaged TPS. Research will also extend to ultra-high-temperature ceramics, ceramic matrix composites, and chemically complex alloys, and high temperature characterization of these systems. Additionally, a software framework will be developed to ensure seamless industry adoption and integration of advanced simulation tools. Multi-fidelity modeling, incorporating machine learning techniques, will enable rapid prototyping and optimization. Collaborative efforts with the Army Research Laboratory (ARL) and other institutions will be essential to achieving these objectives, ensuring robust validation and practical implementation of new technologies.