Novel Multi-scale/Multi-physics Integrated Tool for the Prediction of Manufacturing-Induced Defects in Autoclave Composite Airframe Parts Navy STTR FY2015.A Sol No.: Navy STTR FY2015.A Topic No.: N15A-T003 Topic Title: Novel Multi-scale/Multi-physics Integrated Tool for the Prediction of Manufacturing-Induced Defects in Autoclave Composite Airframe Parts Proposal No.: N15A-003-0115 Firm: Technical Data Analysis, Inc. 3190 Fairview Park Drive Suite 650 Falls Church, Virginia 22042 Contact: Nicole Apetre Phone: (703) 226-4076 Abstract: Composite materials have emerged as the materials of choice for increasing the performance and reducing the weight and cost of military aircraft. Nevertheless, manufacture of composite parts still poses numerous difficulties which can result in premature curing, degradation in thin cross-sections, incomplete curing in thick counterparts or build-up of internal stresses. Experimental investigations of the cure and rheology of the composites can be effective for understanding how a manufacturing process can result in the highest quality components. This empirical approach can be very complex to set-up and time consuming to execute. Numerical modeling and simulations are much more cost effective alternatives to in-situ empirical trials for such processes. In this STTR effort, TDA's team and its university partner, Missouri University of Science and Technology (Prof. K. Chandrashekhara) will be focusing on building a virtual autoclave which will (a) ease the burden of experiments, (b) provide the evolution of volumetric changes, residual stresses and process-induced distortions and (c) include advanced optimization features. The required analytical solutions are developed in the framework of finite element model by suitable micromechanical computations and stochastic methodologies. Lessons learned in the laboratory will be used to model manufacturing defects in a virtual environment. Benefits: TDA envisions as a final product of this research effort a well validated, state-of-the-art, accurate and computationally efficient virtual tool focused on autoclave process of composite manufacturing. This product will be based on a multi-scale/multi-physics stochastic framework given by a set of computational and analytical tools in a framework that describes damage accumulation in composite materials from manufacturing configurations. The framework will also include optimization features such as cure times or optimal pressure for a complex component. This will ease the burden of the trial-and-error approach of experiments, will provide engineers better selection criteria for materials and processes, will improve existing materials and manufacturing processes to design against damage. The customizable tool as envisioned in this effort could be used in many industries such as aerospace, automotive or machinery to significantly improve the reliability of various systems. Return