A Multiscale-Multiphysics Tool for Linking Coupon to Component Behavior of CMCs in Relevant Service Environment

ABSTRACT:The main objective of the proposed work is to develop and implement a Multiscale-Multiphysics analysis tool for design, development and analysis CMC components. The multiscale-multiphysics analysis methodology will effectively capture the complex multi-axial stress states in SiC-SiC based CMC sub-elements and components under relevant operating conditions. The unique features of the Multiscale-Multiphysics analysis tool are as enumerated below: Ability to model inherent heterogeneities including manufacturing defects that exist at the microscale and upscale their effect on the response at the structural scale Micromechanics models at the fine scale of interest to characterize damage and failure in the CMC constituent phases Coupled multiphysics based models to determine the environmental degradation of mechanical properties due to oxygen embrittlement at elevated temperatures A temporal-multiscale approach based fatigue life prediction model Material calibration module to characterize properties of the fine scale constituents Model reduction techniques for robustness and computation efficiency The deliverable will be in the form of a plugin for Abaqus or any other commercial finite element (FE) package used by OEMs. The software tool is envisaged to facilitate OEMs in testing of new designs and offer tremendous savings in cost and time during the development process prior to full scale component testing. BENEFIT:The current thrust areas for technology development in CMCs include small component fabrication, ceramic joining and integration, material and component testing and characterization and design and analysis of concept components. As these manufacturing technologies mature, more and more of the metal-alloy based hot section components will be replaced by components made from CMCs. And as the applications of CMCs grow, the market for failure and fatigue life prediction technologies is also expected to grow significantly. The proposed comprehensive analysis tool will not only allow for strength and life prediction of CMC sub-elements and components, but also create a general framework for future development. The features of the spatial-multiscale approach allows microstructural details including imperfections to be taken into account. The multiphysics aspect incorporates constitutive relations to model coupled physical phenomena occurring at the microstructural length scale. The temporal multiscale feature allows the physical phenomena of cyclic loading and the resulting damage progression to be resolved under disparate time scales. These fundamental features of the proposed approach are essential in the softwares ability to reliably and accuracy predict the response of CMC components. The tool will assist OEMs in characterizing CMC material properties based on coupon testing and then use these validated models in component testing. The tool is also envisaged to promote design, development and testing of concept components and offer tremendous savings in cost and time. The technology developed under this SBIR project, has the potential to generate numerous opportunities for commercialization. Through direct cooperation with prospective OEMs and AFRL, we will initiate the commercialization process through technology insertion into this initial group of highly-motivated end-users. In addition, implementation of the tool as an Abaqus plugin provides access to a Simulias customer base which includes a number of aerospace, mechanical, civil, offshore, shipbuilding and transportation industries. Our strategic partnership with Simulia increases the opportunity of commercialization of the technology proposed here.