Toolset for Nonlinear Prediction of Woven Ceramic Matrix Composite Material Performance
Navy SBIR FY2014.1

Sol No.: Navy SBIR FY2014.1
Topic No.: N141-082
Topic Title: Toolset for Nonlinear Prediction of Woven Ceramic Matrix Composite Material Performance
Proposal No.: N141-082-0019
Firm: ATA Engineering, Inc
13290 Evening Creek Drive South
Suite 250
San Diego, California 92128-4695
Contact: Shane Flores
Phone: (310) 341-0387
Web Site:
Abstract: ATA Engineering, Inc., proposes to develop improved nonlinear material behavior models for the design of 2D and 3D woven carbon/carbon (C/C) composite thermal protection system (TPS) components. The objective of this work is to enable efficient design of 3D C/C composite TPS components and decrease the costs associated with developing new C/C composite materials. ATA's approach combines (1) probabilistic MCMC simulation to autonomously identify constituent and interface parameters for the material models that correlate to test data most accurately, (2) a GUI for unit cell design allowing rapid trade studies based on a micromechanics approach, also to serve as a preprocessor for the Abaqus coupled thermal-stress simulations, (3) a refined and efficient physics-based FEA of C/C unit cells that accounts for details of fiber, matrix, and interface behavior, using Abaqus to simulate the nonlinear response of woven composites subject to steady-state and transient pressure and thermal loads, and (4) stochastic Monte Carlo simulation to address variability in material properties and unit cell topology. Phase I will focus on demonstrating the feasibility of the proposed approach by aiming to simulate the response of a woven C/C unit cell under the conditions of a standard thermal shock test.
Benefits: The envisioned product is a holistic tool that is integrated as a module or extension for existing computer-aided engineering (CAE) software tools across the aerospace, electronic packaging, automotive, and nuclear energy industries. While making up a diverse portfolio including applications for missile nose tips, hypersonic aircraft leading edges, and even brake rotors for Formula 1 race cars, products in these sectors all experience severe transient thermal environments. This thermal loading commonly results in progressive damage and material non-linearity that must be adequately characterized to accurately predict the performance of the constituent composite materials and the system's structural performance. The proposed framework for improved material property, behavior, and failure mode prediction will speed time-to-market of new and innovative materials across these industries.