ICME Lifing Model of CMC Coupons using Nano-Micro-Mechanics Based Multi-Scale Progressive Failure Analysis

2021 ◽  
Author(s):  
Frank Abdi ◽  
Dr. Harsh Baid ◽  
Dr. Dade Huang
Keyword(s):  
Failure Analysis ◽  
Progressive Failure ◽  
Multi Scale ◽  
Progressive Failure Analysis

Foreign Object Damage and Fatigue After Impact Simulations on Flat and Curved Hi Nicalon and Hi Nicalon Type S (MI SiC) Specimens at Room and 1200°C Using Building Block Approach

2016 ◽  
Author(s):  
Frank Abdi ◽  
Cody Godines ◽  
Gregory N. Morscher ◽  
Sung Choi ◽  
Marc Villa Montero ◽  
...  
Keyword(s):  
Fatigue Life ◽  
Failure Analysis ◽  
Building Block ◽  
Progressive Failure ◽  
Foreign Object ◽  
Foreign Object Damage ◽  
Multi Scale ◽  
Progressive Failure Analysis ◽  
Damage And Fracture ◽  
Validation Strategy

SiC-based ceramic matrix composites (CMC) in turbine engine applications must sustain fatigue residual life after foreign object impacts that might occur in services. Experiments, nondestructive evaluations (NDE), and simulations have illustrated good correlations between impact energy and foreign object damage (FOD) and fatigue life after impact at room and 1200°C temperatures. Flat and curved five-harness satin (5HS) woven CMCs specimens, consisting of Hi-Nicalon Type S (Goodrich) and Hi-Nicalon (Rolls Royce) in MI SiC matrix, were tested and simulated. Tests measured electrical resistivity (ER), acoustic emission (AE), and microscopy. Simulations used a building block validation strategy and the Multi-Scale Progressive Failure Analysis (MS-PFA) method. Simulations complemented experiments in understanding and predicting the damage states, of impact, and fatigue residual strength after impact of CMCs to form a more complete understanding of the damage mechanisms involved in such events. The GENOA software developed by Alpha STAR Corporation [1, 2, 3] is capable of Durability and Damage Tolerance (D&DT), life, and reliability predictions by means of multi-scale progressive failure analysis (damage and fracture evolution). In general, CMCs are modeled using effective fiber, matrix, and interface constitutive behaviors, from which the lamina stiffness, strengths, and the strain rate effect can be derived. Similarly, the fatigue strength and stiffness degradation, and the effect of defects in a matrix micro crack density, voids, as well as fibers waviness, and damages after impact can be characterized. The final simulation is static loading and impact on a generic CMC SiC/SiC (Sylramic MI 5HS) blade which is to be used in future blade optimization based on minimizing damage incurred. The GENOA software platform supports FAA recommended ASTM standard Building-Block Validation Strategy with reduced tests conducting: 1) Material Calibration and Qualification, and 2) FEM Verification, Validation, and 3) Blind Predictions (Accreditation). The simulation and test comparisons performed included the damage size for both the CMC (fracture) and the steel impactor (plastic deformation), rebound velocities, SN curves for fatigue of pristine and impacted specimens at room and high temperatures. All simulations showed good correlation. The MS-PFA tool demonstrated a great potential for CMC post FOD fatigue life for part certification supported with reduced tests.

Damage-tolerant composite design principles for aircraft components under fatigue service loading using multi-scale progressive failure analysis

2017 ◽  
Vol 51 (15) ◽  
pp. 2181-2202 ◽  
Author(s):  
Saber DorMohammdi ◽  
Cody Godines ◽  
Frank Abdi ◽  
Dade Huang ◽  
Massimiliano Repupilli ◽  
...  
Keyword(s):  
Cyclic Loading ◽  
Failure Analysis ◽  
Air Force ◽  
Progressive Failure ◽  
Stiffness Degradation ◽  
Multi Scale ◽  
Progressive Failure Analysis ◽  
Damage And Fracture ◽  
Open Hole ◽  
Air Force Research Laboratory

Virtual testing has lately gained widespread acceptance among scientists as a simple, accurate, and reproducible method to determine the mechanical properties of heterogeneous microstructures, early in the production process. As a result of the rapid expansion of the use of composites in aerospace design, virtual testing techniques are, in fact, deemed extremely useful to eliminate unnecessary tests and to reduce cost and time associated with generating allowables for lengthy lifing analyses of structures. Leveraging on a limited set of experimental data, a Progressive Failure Analysis can accurately predict the life and safety of a component/assembly, simply tapping on the physics of its micro-/macro- mechanics material properties, manufacturing processes, and service environments. The robust methodology is showcased using blind predictions of fatigue stiffness degradation and residual strength in tension and compression after fatigue compared with test data from Lockheed Martin Aeronautics and Air Force Research Laboratory). The multi-scale progressive failure analysis methodology in the GENOA software considers uncertainties and defects and evaluated the damage and fracture evolution of three IM7-977-3 laminated composite layups at room temperature. The onset and growth of composite damage was predicted and compared with X-ray CT. After blind predictions, recalibrations were performed with knowledge of the test data using the same set of inputs for all layups and simulations. Damage and fracture mechanism evolution/tracking throughout the cyclic loading is achieved by an integrated multi-scale progressive failure analysis extended FEM solution: (a) damage tracking predicts percentage contributing translaminar and interlaminar failure type, initiation, propagation, crack growth path, and observed shift in failure modes, and (b) fracture mechanics (VCCT, DCZM) predicts crack growth (Crack Tip Energy Release Rate vs. Crack Length), and delamination. The predictive methodology is verified using a building block validation strategy that uses: (a) composite material characterization and qualification (MCQ) software, and (b) the GENOA multi-scale progressive failure analysis fatigue life, stiffness degradation, and post-fatigue strength predictions for open-hole specimens under tension/compression at RTD. The unidirectional tension, compression, and in-plane shear lamina properties supplied by Lockheed Martin Aeronautics and the Air Force Research Laboratory (based on the D3039, D638, D3518 tests) were used by MCQ to reverse engineer effective fiber and matrix static and fatigue properties for the IM7-977-3 material system. The use of constituent properties identified the root cause problem for composite failure and enabled the detection of damage at the micro-scale of the material where damage is incepted. For all three case studies (namely, layups [0/45/90/−45]2s, [+60, 0, −60]3s, and [+30, +60, 90, −60, −30]2s), the blind predictions on the fatigue stiffness degradation and residual strength of the open-hole coupon in tension/compression under cyclic loading (with R = 0.1) at RTD were evaluated using a FE mesh (made of 2k shell elements), in which only one shell element, containing all plies, was employed through the thickness. The results of all analyses correlated very well with the tests, including the damage micro-graphs generated during the cyclic loading.

Damage tolerant composite design principles for aircraft components under static service loading using multi-scale progressive failure analysis

2016 ◽  
Vol 51 (10) ◽  
pp. 1393-1419 ◽  
Author(s):  
Cody Godines ◽  
Saber DorMohammadi ◽  
Frank Abdi ◽  
Marc Villa Montero ◽  
Dade Huang ◽  
...  
Keyword(s):  
Failure Analysis ◽  
Air Force ◽  
Test Data ◽  
Building Block ◽  
Research Laboratory ◽  
Progressive Failure ◽  
Design Principles ◽  
Multi Scale ◽  
Progressive Failure Analysis ◽  
Air Force Research Laboratory

The overall objective of this effort was to provide theoretical prediction for damage development for a set of laminated composites using Alpha STAR Corporations’ commercial code GENOA (GENeral Optimization Analyzer) for the Air Force Research Laboratory program entitled “Damage Tolerance Design Principles (DTDP)”. Damage progression and prediction for advance composite benchmarks were done under static and fatigue service loading using test data from Lockheed Martin Aeronautics and Air Force Research Laboratory. In the current paper, the results for the static analysis are presented. Emerging and innovative multi-scale (MS) modeling using computational structural mechanics and progressive failure analysis were proven to address the Air Force’s vision to perform predictive evaluation of composite materials using a building block validation strategy and certification process. Three layups were tested in tension and compression for unnotched and openhole configurations. Calibration of the fiber and matrix properties was performed using in plane, 3pt bend and DCB test data. After this, mesh convergence, solver selection based on CPU time, and mesh sensitivities was performed. The static blind simulations of strength showed an average error of 12.9% between simulation and the test data. For stiffness, the percent difference was found to be 23.5% on average. Although the focus was on the ability to blindly predict test data, recalibration efforts show an average of 9.2% difference between simulation and test for strengths and 12.4% for stiffness computations. Damage at ∼60–75% and ∼90% of max loading was comparable with X-ray observations of specimens set aside solely for that purpose. All simulations used the same set of inputs (constituents, voids, fiber waviness, etc.) except for the noted analysis setting differences between blind and recalibration simulations. The method is consistent and follows a building block simulation approach that has an advanced yet simplistic theoretical multi-scale progressive failure analysis approach all contained in the commercial GENOA software. The method was demonstrated to work having GENOA directly run sequential NASTRAN simulations and, post project completion, with the ABAQUS solver using GENOA as a material subroutine.

Progressive Failure Analysis of Thin Walled Composite Tubes Under Low Energy Impact

2007 ◽  
Author(s):  
Chian-Fong Yen ◽  
Thomas Cassin ◽  
Joel Patterson ◽  
Matt Triplett
Keyword(s):  
Failure Analysis ◽  
Progressive Failure ◽  
Low Energy ◽  
Composite Tubes ◽  
Energy Impact ◽  
Progressive Failure Analysis ◽  
Thin Walled

Progressive failure analysis of thin-walled composite structures

2013 ◽  
Vol 95 ◽  
pp. 53-62 ◽  
Author(s):  
Diego Cárdenas ◽  
Hugo Elizalde ◽  
Piergiovanni Marzocca ◽  
Frank Abdi ◽  
Levon Minnetyan ◽  
...  
Keyword(s):  
Failure Analysis ◽  
Composite Structures ◽  
Progressive Failure ◽  
Progressive Failure Analysis ◽  
Thin Walled
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