Certification Modeling for Composites with Voids and Wrinkles for Engines and Structures

This SBIR will model the effects of voids/wrinkles on interlaminar strength and fatigue, detect defect locations, test curved specimens; and develop void/wrinkle generation models for contoured composite structures to improve their integrity and reduce rejection rates. Accordingly, the target contribution of this effort has been summarized as understanding the effects of void and wrinkling defects on structural integrity such that useful accept/reject criteria can be developed leading to reduced conservatism; and understanding generation of the critical defects including their location, size and shape; and possibly developing practical engineering criteria quantifying the critical defects. Wrinkles and voids at ply interfaces are the most dangerous manufacturing defects in contoured composite parts. The proposed effort will fill the major gaps in analysis techniques by developing practical tools capturing the formation of the critical defects as well as their effects on structural integrity. Ply-level modeling of the defects formation as well as their effects on strength and fatigue performance eliminates the risks associated with the standing challenges of connecting modeling scales, and presents an outstanding opportunity for a successful two-year Phase II software development effort leading to Certification Modeling of Composites with Voids and Wrinkles for Engines and Structures.