I-Corps: Software tools to model the progressive failure of polymer matrix composite structures

Award ID: 2232252

The broader impact/commercial potential of this I-Corps project is the development of software tools to model the progressive failure of composite structures used in aerospace applications. Failure modeling of composites is a highly complex multiscale problem, and the result of the analysis implies a trade between fidelity and speed depending on the scale at which damage is simulated and the size of the structure. The proposed technology provides a general framework to analyze combinations of layups and loading scenarios using a common experimental material characterization plan. The technology incorporates the effect of manufacturing on the performance of the structure. By advancing simulation tools, composite structures may be designed with more confidence and safety as well as in a much shorter time frame compared to current procedures. The availability of reliable and fast predictive tools may enable and accelerate the use of lightweight composite materials, which in turn may lead to better fuel efficiency of commercial and military aircraft. This I-Corps project is based on the development of a finite element algorithm that models explicitly the dominating damage modes observable at the subcomponent level of a composite structure such as delamination, macroscopic matrix cracking, and splitting. This analysis level is the most time consuming and expensive in the certification process of a structure. The proposed technology may be used to accelerate the certification process without compromising accuracy by identifying a set of fundamental model features, characterizable from basic coupon tests, that must be incorporated to predict the progressive failure of composite structures in a wide range of layups and loading scenarios. In tests of the proposed technology, errors within 5% of experimental data in blind predictions are typically achieved in computational times of one order of magnitude faster than current methods. In addition, the analysis also considers the effects of the curing process, which affects the residual stresses and deformations in the composite. These factors influence mechanical properties such as stiffness and strength. The proposed technology integrates curing and failure modeling within the same finite element software. This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

NSF Program Director: Ruth Shuman