Alexander Safonov

Prof. Safonov’s research work currently focuses on developing the pultrusion process to fabricate structural profiles of fiber reinforced thermoplastic materials. Thermoplastic composites offer several advantages such as higher crack resistance and damage tolerance due to the higher ultimate strain of matrix; shorter production cycle due to the absence of chemical reactions during fabrication; excellent environmental resistance; and thermoforming capabilities as thermoplastic matrix melts under high temperatures without chemical destruction. The main goal is to develop the process to fabricate of structural profiles and structures of fiber reinforced thermoplastic materials, capable to compete with and outperform those of traditional thermoset materials.

• Moskaleva, A.; Gusev, S.; Konev, S.; Hernandez-Montes, E.; Safonov, A. Stiffening patterns for freeform composite shell structures. Thin-Walled Structures 2024, 201, 112037, doi:10.1016/j.tws.2024.112037
• Elkin, A.; Konev, S.; Safonov, A.; Gusev, S.; Sergeichev, I. Compressive residual strength of the pultruded glass-fiber composite after tension-compression fatigue. Composites Part C: Open Access 2024, 14, 100456, doi:10.1016/j.jcomc.2024.100456
• Kravtsova, V.; Minchenkov, K.; Gusev, S.; Evlashin, S.; Bondareva, J.; Alajarmeh, O.; Safonov, A. Recyclability of unidirectional reinforced pultruded thermoplastic profiles into composite laminates. Composites Communications 2024, 46, 101843, doi:10.1016/j.coco.2024.101843
• Minchenkov, K.; Gusev, S.; Rogozheva, A.; Tronin, A.; Diatlova, M.; Safonov, A. Pultrusion of thermoplastic composites with mechanical properties comparable to industrial thermoset profiles. Composites Communications 2023, 44, 101766, doi:10.1016/j.coco.2023.101766
• Minchenkov, K.; Gusev, S.; Sulimov, A.; Alajarmeh, O.; Sergeichev, I.; Safonov, A. Experimental and numerical analyses of the thermoplastic pultrusion of large structural profiles. Materials & Design. 2023, 232, 112149, doi:10.1016/j.matdes.2023.112149
• Romanovskaia, N.; Minchenkov, K.; Gusev, S.; Klimova-Korsmik, O.; Safonov, A. Effects of Additives on the Mechanical and Fire Resistance Properties of Pultruded Composites. Polymers 2023, 15, 3581. doi:10.3390/polym15173581
• Safonov, A.; Minchenkov, K. Mathematical Simulation of Honeycomb Weathering via Moisture Transport and Salt Deposition. Geosciences 2023, 13, 161. doi:10.3390/geosciences13060161
• Alajarmeh, O.; Manalo, A.; Ferdous, W.; Almasabha, G.; Tarawneh, A.; Awwad, K.E.; Safonov, A.; Zeng, X.; Schubel, P.  Fatigue behavior of unidirectional fiber‐reinforced pultruded composites with high volume fiber fraction. Fatigue & Fracture of Engineering Materials & Structures 2023, 46, 6, doi:10.1111/ffe.13979
• Bondareva, J.V.; Chernodoubov, D.A.; Dubinin, O.N.; Tikhonov, A.A.; Simonov, A.P.; Suetin, N.V.; Tarkhov, M.A.; Popov, Z.I.; Kvashnin, D.G.; Evlashin, S.A.; Safonov, A.A. Thermal and Electrical Properties of Additively Manufactured Polymer–Boron Nitride Composite. Polymers 2023, 15, 1214, doi:10.3390/polym15051214
• Moskaleva, A.; Gusev, S.; Konev, S.; Sergeichev, I.; Safonov, A.; Hernandez-Montes, E. Composite freeform shell structures: Design, construction and testing. Composite Structures 2023, 306, 116603, doi:10.1016/j.compstruct.2022.116603
• Vedernikov, A.; Gemi, L.; Madenci, E.; Onuralp Özkılıç, Y.; Yazman, Ş.; Gusev, S.; Sulimov, A.; Bondareva, J.; Evlashin, S.; Konev, S.; Akhatov, I.; Safonov, A. Effects of high pulling speeds on mechanical properties and morphology of pultruded GFRP composite flat laminates. Composite Structures 2022, 301, 116216, doi:10.1016/j.compstruct.2022.116216
• Minchenkov, K.; Vedernikov, A.; Kuzminova, Y.; Gusev, S.; Sulimov, A.; Gulyaev, A.; Kreslavskaya, A.; Prosyanoy, I.; Xian, G.; Akhatov, I.; Safonov, A. Effects of the quality of pre-consolidated materials on the mechanical properties and morphology of thermoplastic pultruded flat laminates. Composites Communications 2022, 35, 101281, doi:10.1016/j.coco.2022.101281
• Gemi, L.; Madenci, E.; Özkılıç, Y.O.; Yazman, Ş.; Safonov, A. Effect of Fiber Wrapping on Bending Behavior of Reinforced Concrete Filled Pultruded GFRP Composite Hybrid Beams. Polymers 2022, 14, 3740. doi:10.3390/polym14183740
• Aksoylu C, Özkılıç YO, Madenci E, Safonov A. Compressive Behavior of Pultruded GFRP Boxes with Concentric Openings Strengthened by Different Composite Wrappings. Polymers 2022; 14(19):4095. doi:10.3390/polym14194095
• Madenci, E.; Özkılıç, Y.O.; Aksoylu, C.; Safonov, A. The Effects of Eccentric Web Openings on the Compressive Performance of Pultruded GFRP Boxes Wrapped with GFRP and CFRP Sheets. Polymers 2022, 14, 4567. doi:10.3390/polym14214567
• Zhou, P.; Li, C.; Bai, Y.; Dong, S.; Xian, G.; Vedernikov, A.; Akhatov, I.; Safonov, A.; Yue, Q. Durability study on the interlaminar shear behavior of glass-fibre reinforced polypropylene (GFRPP) bars for marine applications. Construction and Building Materials 2022, 349, 128694, doi:10.1016/j.conbuildmat.2022.128694
• Novikov, I. V.; Krasnikov, D. V.; Vorobei, A.M.; Zuev, Y.I.; Butt, H.A.; Fedorov, F.S.; Gusev, S.A.; Safonov, A.A.; Shulga, E. V.; Konev, S.D.; Sergeichev, I.V; Zhukov, S.S.; Kallio, T.; Gorshunov, B.P.; Parenago, O.O.; Nasibulin, A.G.   Multifunctional Elastic Nanocomposites with Extremely Low Concentrations of Single-Walled Carbon Nanotubes. ACS Applied Materials & Interfaces 2022, 14, 18866–18876, doi:10.1021/acsami.2c01086
• Vedernikov, A.; Minchenkov, K.; Gusev, S.; Sulimov, A.; Zhou, P.; Li, C.; Xian, G.; Akhatov, I.; Safonov, A. Effects of the Pre-Consolidated Materials Manufacturing Method on the Mechanical Properties of Pultruded Thermoplastic Composites. Polymers 2022, 14, 2246. doi:10.3390/polym14112246
• Korotkov, R.; Vedernikov, A.; Gusev, S.; Alajarmeh, O.; Akhatov, I.; Safonov, A. Shape memory behavior of unidirectional pultruded laminate. Composites Part A: Applied Science and Manufacturing 2021, 150, 106609, doi:10.1016/j.compositesa.2021.106609.
• Moskaleva, A.; Safonov, A.; Hernández-Montes, E. Fiber-Reinforced Polymers in Freeform Structures: A Review. Buildings 2021, 11, 481, https://doi.org/10.3390/buildings1110048.
• Alajarmeh, O.; Zeng, X.; Aravinthan, T.; Shelley, T.; Alhawamdeh, M.; Mohammed, A.; Nicol, L.; Vedernikov, A.; Safonov, A.; Schubel, P. Compressive behaviour of hollow box pultruded FRP columns with continuous-wound fibres. Thin-Walled Structures 2021, 168, 108300, doi:10.1016/j.tws.2021.108300.
• Vedernikov, A.; Safonov, A.; Tucci, F.; Carlone, P.; Akhatov, I. Modeling Spring-In of L-Shaped Structural Profiles Pultruded at Different Pulling Speeds. Polymers 2021, 13, 2748, doi:10.3390/polym13162748.
• Popov, D.; Kuzminova, Y.; Maltsev, E.; Evlashin, S.; Safonov, A.; Akhatov, I.; Pasko, A. CAD/CAM System for Additive Manufacturing with a Robust and Efficient Topology Optimization Algorithm Based on the Function Representation. Applied Sciences 2021, 11, 7409, doi:10.3390/app11167409.
• Vedernikov, A.; Nasonov, Y.; Korotkov, R.; Gusev, S.; Akhatov, I.; Safonov, A. Effects of additives on the cure kinetics of vinyl ester pultrusion resins. Journal of Composite Materials  2021, doi:10.1177/00219983211001528.
• Minchenkov, K.; Vedernikov, A.; Safonov, A.; Akhatov, I. Thermoplastic pultrusion: A review. Polymers 2021, 13(2), 180, doi:10.3390/polym13020180.
• Vedernikov, A.; Tucci, F.; Carlone, P.; Gusev, S.; Konev, S.; Firsov, D.; Akhatov, I.; Safonov, A. Effects of pulling speed on structural performance of L-shaped pultruded profiles. Composite Structures 2021, 255, 112967, doi:10.1016/j.compstruct.2020.112967.
• Safonov, A.; Maltsev, E.; Chugunov, S.; Tikhonov, A.; Konev, S.; Evlashin, S.; Popov, D.; Pasko, A.; Akhatov I. Design and Fabrication of Complex-Shaped Ceramic Bone Implants via 3D Printing Based on Laser Stereolithography. Applied Sciences 2020, 10(20), 7138, doi:10.3390/app10207138.
• Vedernikov, A.; Safonov, A.; Tucci, F.; Carlone, P.; Akhatov, I. Pultruded materials and structures: A review. Journal of Composite Materials 2020, 54, 4081–4117, doi:10.1177/0021998320922894.
• Safonov, A.; Filippi, M.; Mašín, D.; Bruthans, J. Numerical modeling of the evolution of arcades and rock pillars. Geomorphology 2020, 365, 107260, doi:10.1016/j.geomorph.2020.107260.
• Safonov, A.; Gusev, M.; Saratov, A.; Konstantinov, A.; Sergeichev, I.; Konev, S.; Gusev, S.; Akhatov, I. Modeling of cracking during pultrusion of large-size profiles. Composite Structures 2020, 235, 111801, doi:10.1016/j.compstruct.2019.111801.
• Nasonov Y.; Safonov A.; Gusev S.; Akhatov I. Effect of additives on cure kinetics of pultrusion resins. Procedia Manufacturing 2020, 47, 920–4,  doi:10.1016/j.promfg.2020.04.283.
• Vedernikov A.; Tucci F.; Safonov A.; Carlone P.; Gusev S.; Akhatov I. Investigation on the Shape Distortions of Pultruded Profiles at Different Pulling Speed. Procedia Manufacturing 2020, 47, 1–5, doi:10.1016/j.promfg.2020.04.107.
• Safonov, A.; Chugunov, S.; Tikhonov, A.; Gusev, M.; Akhatov, I. Numerical simulation of sintering for 3D-printed ceramics via SOVS model. Ceramics International 2019, 45, 19027–19035, doi:10.1016/j.ceramint.2019.06.144.
• Safonov, A.A. 3D topology optimization of continuous fiber-reinforced structures via natural evolution method. Composite Structures 2019, 215, 289–297, doi:10.1016/j.compstruct.2019.02.063.
• Salimon, A.I.; Statnik, E.S.; Zadorozhnyy, M.Y.; Senatov, F.S.; Zherebtsov, D.D.; Safonov, A.A.; Korsunsky, A.M. Porous Open-Сell UHMWPE: Experimental Study of Structure and Mechanical Properties. Materials 2019, 12, 2195, doi:10.3390/ma12132195.
• Safonov, A.A.; Carlone, P.; Akhatov, I. Mathematical simulation of pultrusion processes: A review. Composite Structures 2018, 184, 153–177, doi:10.1016/j.compstruct.2017.09.093.
• Safonov, A.; Adamatzky, A. Computing via material topology optimisation. Applied Mathematics and Computation 2018, 318, 109–120, doi:10.1016/j.amc.2017.08.030.
• Safonov, A.A. Computing via natural erosion of sandstone. International Journal of Parallel, Emergent and Distributed Systems 2018, 33, 742–751, doi:10.1080/17445760.2018.1455836.
• Ostanin, I.; Safonov, A.; Oseledets, I. Natural Erosion of Sandstone as Shape Optimisation. Scientific Reports 2017, 7, 17301, doi:10.1038/s41598-017-17777-1.
• Shakhova, I.; Mironov, E.; Azarmi, F.; Safonov, A. Thermo-electrical properties of the alumina coatings deposited by different thermal spraying technologies. Ceramics International 2017, 43, 15392–15401, doi:10.1016/j.ceramint.2017.08.080.
• Dubinskii, S. V.; Safonov, A.A. Composite-friendly approach to certification of advanced materials and fabrication methods used in aviation industry. Journal of Machinery Manufacture and Reliability 2017, 46, 501–506, doi:10.3103/S1052618817050041.
• Tinkov, D.V.; Safonov, A.A. Design optimization of truss bridge structures of composite materials. Journal of Machinery Manufacture and Reliability 2017, 46, 46–52, doi:10.3103/S1052618817010149.
• Fedulov, B.N.; Safonov, A.A.; Kantor, M.M.; Lomov, S. V. Modelling of thermoplastic polymer failure in fiber reinforced composites. Composite Structures 2017, 163, 293–301, doi:10.1016/j.compstruct.2016.11.091.
• Safonov, A.; Jones, J. Physarum computing and topology optimisation. International Journal of Parallel, Emergent and Distributed Systems 2017, 32, 448–465, doi:10.1080/17445760.2016.1221073.
• Fedulov, B.; Fedorenko, A.; Safonov, A.; Lomakin, E. Nonlinear shear behavior and failure of composite materials under plane stress conditions. Acta Mechanica 2017, 1–8, doi:10.1007/s00707-017-1817-4.
• Fedulov, B.N.; Safonov, A.A.; Sergeichev, I. V.; Ushakov, A.E.; Klenin, Y.G.; Makarenko, I. V. Strength Analysis and Process Simulation of Subway Contact Rail Support Bracket of Composite Materials. Applied Composite Materials 2016, 23, 999–1013, doi:10.1007/s10443-016-9495-2.
• Fedulov, B.; Antonov, F.; Safonov, A.; Ushakov, A.; Lomov, S. Influence of fibre misalignment and voids on composite laminate strength. Journal of Composite Materials 2015, 49, 2887–2896, doi:10.1177/0021998314557533.
• Ushakov, A.E.; Safonov, A.A.; Sergeichev, I. V.; Fedulov, B.N.; Kornienko, E.I.; Timofeev, M.A.; Izotov, A. V.; Klenin, Y.G.; Rozin, N. V. Design and optimization of a vacuum infusion technological process for hopper car fabrication using polymeric composite materials. Journal of Machinery Manufacture and Reliability 2015, 44, 276–282, doi:10.3103/S105261881503022X.
• Sergeichev, I.V.; Antonov, F.K.; Safonov, A.A.; Ushakov, A.E. Estimation of residual strength of components of composite constructions after low-speed impact. Journal of Machinery Manufacture and Reliability 2013, 42, doi:10.3103/S1052618813010111.
• Shcheglov, B.A.; Safonov, A.A. Methods for determining the permeability of an orthotropic medium. Journal of Machinery Manufacture and Reliability 2012, 41, 229–236, doi:10.3103/S1052618812030090.
• Safonov, A.A.; Shcheglov, B.A. Mathematical modeling of polymerization in the manufacturing of polymeric composite materials. Journal of Machinery Manufacture and Reliability 2011, 40, doi:10.3103/S105261881106015X.
• Safonov,  A. A. Mathematical description of the technological process of injection pultrusion. Journal of Machinery Manufacture and Reliability 2011, 40, 68–73, doi:10.3103/S1052618811010171.
• Sorina, T.G.; Safonov, A.A.; Khairetdinov, A.K. Pecularities of using carbon glass-reinforced plastic in pultrusion composite profiles for bridge engineering. Journal of Machinery Manufacture and Reliability 2010, 39, doi:10.3103/S1052618810010073.
• Safonov, A.A. Mathematical modeling for impregnation of reinforcing filler of fiberglasses during vacuum infusion. Journal of Machinery Manufacture and Reliability 2010, 39, 568–574, doi:10.3103/S1052618810060105.
• Safonov, A.A.; Suvorova, Y.V. Optimization of the pultrusion process for a rod with a large diameter. Journal of Machinery Manufacture and Reliability 2009, 38, doi:10.3103/S1052618809060090.

Advanced Manufacturing of Composite Materials (6 credits)

This course is developed to give students a broad background and hands on experience in manufacturing of advanced composite materials. Both materials and manufacturing methods are discussed. A brief introduction to advanced composite materials and processes is presented. The course is focused on the innovative non-autoclave technologies of thermosetting resin based/fiber reinforced advanced composites. Manufacturing is covered in terms of the major steps required to fabricate laminated composite parts. These will be described and discussed in details and worked out experimentally through conducting a set of lab projects. The following technologies and methods will be covered: Vacuum Infusion, Press Molding, Pultrusion, Filament Winding, and Mechanical Testing. Typical problems of materials, tooling, cure, and technological defects will be discussed.

Structural Optimization (6 credits)

The course is intended to give basic knowledge and skills how to formulate a structural optimization problem, including defining appropriate design variables, constraints, and objective functions. The main topics of the course are classification of structural optimization problems, calculus of variations and energy principles in solid mechanics, structural approximations, sensitivity analysis, optimality criteria, shape optimization, structures of maximum stiffness and topology optimization, SIMP-method. Computer exercises on structural optimization will be performed.

Study explores way to make PVC windows warmer and add recyclable components

Computer simulation explains mysterious rock patterns seen from Czech Republic to Mars

Reinventing building design to unlock composite materials’ potential for architecture

High-strength pultruded thermoplastic composites made of new raw material

Scientists explore method to produce composites with ‘shape memory’

Skoltech scientists find a way to make pultrusion faster

Skoltech scientists study thermoplastic pultrusion and patent fiber-reinforced pultruded thermoplastic profile

Skoltech scientists obtain a patent for a novel window thermal insulation enhancement method

Skoltech scientists optimized productivity of pultrusion manufacturing process

Scientists developed a novel bone implant manufacturing method

Scientists modelled natural rock arcades

Mathematicians crack the mystery of natural pillars and arches

Skoltech scientists explained how the process of erosion forms unusual shapes and structures

ФИО: Сафонов Александр Александрович
Занимаемая должность: Доцент
Преподаваемые дисциплины: Технологии производства изделий из композиционных материалов
Ученая степень: Кандидат технических наук 2006, Институт машиноведения им. А.А. Благонравова Российской академии наук (ИМАШ РАН), Москва
Наименование направления подготовки и/или специальности: Физико-математические науки
Общий стаж работы: Более 18 лет
Стаж работы по специальности: Более 18 лет