Innovative Multi-scale/Multi-physics based Tool for Predicting Fatigue Crack Initiation and Propagation in Aircraft Structural Components using Phase

A multi-scale/multi-physics integrated tool will be developed to predict fatigue crack initiation and propagation in a metallic structure by bridging the length scale from its polycrystals microstructure to a smeared continuum of its complex geometry. In order to simulate the microstructure and localized plasticity driven crack initiation, its micro-growth within a grain or across several grains, and its macro-growth that leads to the final rupture of an aircraft structural component, a fast Fourier transform (FFT) based computational approach integrating phase-field method (PFM) and crystal plasticity (-pro) developed by Prof. Chens research group at the Pennsylvania State University (PSU) will be enhanced and integrated with our 3D extended finite element toolkit for Abaqus (XFA3D). The effects of plasticity will be included for characterization of crack nucleation, its transition to a short crack, and its transition from a short crack to a long crack that will be governed by a linear fracture mechanics theory. A well balanced modeling accuracy and computational efficiency along with our newly implemented isogeometric solution capability in the integrated toolkit will offer its broad use for life prediction of large scale complex structures. GEM has already secured commitments from PSU for the success of the proposed work.