Engineering a Research Career with Impact

In the field of mechanical and aeronautical engineering, one route to sustainability is to increase the durability, maintainability and resilience of materials, which extends the working life of structures and enhances structural safety, thereby reducing energy consumption and waste.  

For Professor Sarah Zhang, this path of research has led to a series of opportunities and in a few short years has propelled her into a leadership position in her field. 

Zhang joined Western in 2019 after 15 years at the University of New South Wales (UNSW). She is a mechanical and structural engineer with expertise in numerical modelling and simulation, focusing on research and development of advanced composite materials and structures. Since joining Western she has developed a strong interest in sustainability and strong leadership especially in defence-related research.  

Zhang has been successful in securing a couple of major projects by the Next Generation Defence Fund, funded by the Department of Defence, to develop nanocomposite adhesives to improve the efficiency, durability and longevity of repairs to key infrastructures especially for aircraft structures, as well as to assess the vulnerability of composite structures against laser weapon attacks and enhance the structural protection capability.   

"These projects are very challenging, but critical and significant to the defence industry and composite manufacturing. They are focused on improving structural performance for key infrastructure made of composites, which are widespread across civilian and defence industries," says Zhang. "I look at both through a sustainability and resilience lens: how we can extend the lifetime of structures through smarter and greener advanced materials and manufacturing technology and processes."

One of the most polluting aspects of construction is the manufacture of the cement used for concrete. The production of ordinary Portland cement (OPC) accounts for up to 8% of global CO2 emissions. Zhang’s first research project with Western was a continuation of the research she started at UNSW on an alternative type of cement, which is environmentally friendly, but has not been widely adopted by the construction industry. 

Magnesium oxychloride cement (MOC) is a 'green' cement produced from industry by-products, especially from magnesium mines, that has been known about for some time. However, "while it is strong and sets quickly, it has low water resistance, which has prevented it from being used externally," explains Zhang.  

Zhang and her team made a breakthrough in recent years and developed a formula using other industry by-products such as fly ash and silica fume. The addition of some acid solved the issue of poor water resistance.  

The new formula led to the microstructure of the cement being set in a way that prevents the material from being weakened by water. The result has been adopted by a local industry partner. 

After that significant win, Zhang started exploring the addition of short fibres to further improve the durability and fire resistance of the green composite and improve its resilience and sustainability.

"Fire resistance under loading is a significant issue for buildings and key infrastructures," Zhang says. "We were awarded a Discovery Projects grant from the Australian Research Council to develop fire resistant composites especially for non-structural application such as claddings." 

Meanwhile, Zhang has worked tirelessly to build the research capacity of the School of Engineering, Design and Built Environment in her disciplinary areas in both mechanical and civil engineering, in particular in advanced materials and manufacturing, and construction sustainability and resilience. 

She is the founding Co-Director of the Centre for Advanced Manufacturing Technology and was the Deputy Director of the Urban Transformations Research Centre at Western. She has also been Western’s discipline lead for Civil and Environmental Engineering and a Research Theme Champion for Environment and Sustainability. In addition to her research agenda, Zhang has been contributing to the University governance and education. She has been working as the Deputy Chair of the Academic Senate since 2021 and as the Acting Chair of the Senate for the second half of 2022.  

"I was fortunate to be given these leadership roles and I received a lot of great support from the University to turn these opportunities into active programmes and outcomes," Zhang says. "Western is such a vibrant and dynamic university, with truly impressive engagement agendas across community and industry, and many dedicated people working so hard and making things happen."