Novel Multi-scale/Multi-physics Integrated Tool for the Prediction of Manufacturing-Induced Defects in Autoclave Composite Airframe Parts

A multi-scale/multi-physics software tool will be developed to predict manufacturing-induced defects, specifically void evolution during composites manufacturing, due to materials, parts, tooling and process parameters. Appropriately modeling the manufacturing process to identify potential problem areas will enable process optimization to produce structural components without defects. Specifically, this STTR will identify the mechanisms behind void evolution and growth during autoclave/out-of-autoclave processing of thermoset prepreg systems, and formulate and develop modeling tools that can predict void evolution as a function of time in a complex geometry composite structure. This STTR will establish the science base and develop models to predict the behavior for each mechanism, validate the models with key experiments, develop integration strategies with commercial codes and provide a graphical user interface that will allow the designer to optimize the manufacturing process. Integration into commercially available finite element design and analysis suites will allow the evaluation of the effect of these defects on the performance of complex geometries in the real processing environments. This STTR will demonstrate the approach on autoclave processing and high-performance composites materials for aerospace structures but the developed methodology can be implemented for a variety of thermoset prepreg processes including out-of-autoclave processing.