ADVANCED DESIGN AND LIFE PREDICTION METHODOLGY FOR POLYMERIC MATRIX COMPOSITE COMPONENTS

Multiscale Design Systems, LLC, in collaboration with domain experts in modeling (Rajagopal), simulation (Estep), experimentation (Ruggles-Wrenn) and in partnership with GE Aviation, Boeing and Renegade Materials, will develop integrated multiscale design software for high temperature polymer matrix component (HTPMC) materials, hereafter referred to as MDS-C. The key functionalities of the MDS-C to be developed are: 1. Deterministic and probabilistic multiscale multiphysics hygro-thermo-mechano-oxidation-fatigue capabilities; 2. Automated design cycle for HTPMC materials including integration of experiments and simulation; 3. Seamless commercial software interface and an intuitive, workable, user-friendly GUI. Phase II demonstrations will compare the MDS-C predictions with the experimental data of PMR-15 and FreeForm 14 based components subjected to various individual and combined environmental conditions, such as hygro-thermo-mechano-oxidation-fatigue environments. For model calibration and validation we will have an access to the NCAMP MVK-14 FreeForm™ Polyimide Composite test database. BENEFIT: Polymer matrix composites used in high-temperature applications, such as turbine engines and engine exhaust washed structures, are known to have limited life due to oxidative, hygrothermal and thermal fatigue degradation. For example, high temperature, pressure, and the presence of moisture limit the life of some polyimide composite components to only 100 h of service for worst-case operational conditions. Therefore, a reliable multiphysics-multiscale simulation model is critical to yield an understanding of the mechanisms behind observed degradation phenomena, help to design accelerated tests and serve as a basis for truly predictive capability. Such a predictive capability will be developed and housed in the Multiscale Design System product line (MDS-C) and will be of immediate use in situations where conventional design procedures for HTPMC component lacked predictability. The MDS-C will provide not only a customizable environment for research into HTPMC materials, but also an integrated engineering design platform for high temperature components. The hygro-thermo-mechano-oxidation-fatigue modeling capabilities will become part of our MDS-C product line and will continue to be evolved to meet more general needs. The three partnerships (GE Aviation, Boeing and Renegade Materials) already established and strong endorsement from six other companies (Northrop-Grumman, Lockheed-Martin, Rolls-Royce Aerospace and Automotive Composites Consortium (ACC) consisting of GM, Ford and Chrysler) are indicative that the proposed life prediction methodology and advanced design tools for HTPMC components will be readily marketable to commercial aircraft and automotive industries.