3D Textile PMC Damage Evolution: Effects of Material State & Morphology Variation

Transcription

1 3D Textile PMC Damage Evolution: Effects of Material State & Morphology Variation Mul:- Scale Structural Mechanics & Prognosis Overview AFOSR PM: Dr. David Stargel 22 July 2013 Integrity «Service «Excellence David Mollenhauer, Rick Hall, Tim Breitzman - AFRL/RXCC 1

2 Outline Project Timeline Project Objec:ves PMC Scales Overview of Tasks Details of Tasks Collabora:ve Possibili:es 2

3 Project Timeline Three Year Effort Scheduled to begin in October 2012 Unfortunately, funding did not arrive un:l June 2013 Sequestra*on related issues This presenta*on is an outline of what was proposed 3

4 Project Objectives Develop knowledge of effects of geometric & material state variability on strength & damage in 3D tex:le composites Geometric: fiber volume frac*on & direc*on, tow & fabric varia*ons Material State: resin cure extent & distribu*on Develop an integrated set of advanced simula:on tools to address the varia:ons of interest Micro- scale & tow- scale variability Mul*- scale Damage evolu*on Advanced chemo- mechanical simula*on method Goal: predic:ve tools to capture variability and its effects in PMCs 4

5 Scales in PMCs Atomistic/Molecular Laminate/Tow Fiber/Matrix Micro-Scale 5

6 Overview of Tasks Task 1: Tow- Level Material Property Varia:on Experimental quan*fica*on of varia*ons of interest at the micro- scale and tow- level (also at lamina- level) Task 2: Tow- Level Morphology Simula:on Enhance exis*ng tex*le morphology simula*on tool to predict tow- level morphology varia*ons and es*mate micro- scale varia*ons Task 3: Mul:- Scale Damage Simula:on & Quan:fica:on Develop simula*on tools to address micro- scale and tow- scale damage evolu*on w/experimental quan*fica*on Task 4: Advanced Mixture Theory Development/Applica:on Development of simula*on technique for resin cure extent & sizing reac*ons and their effects on sta*c and fa*gue 6

7 Tow-Level Material Property Variations (Task 1) Purely Experimental Task Manufacture/obtain specimens (laminates and 3D tex*les) Tow- level cross- sec*onal shape varia*ons Fiber- volume varia*ons (within a lamina and/or tows) Resin cure extent and interphase property varia*ons 3D Weaving Machine 7

8 Tow-Level Material Property Variations (Task 1) Fiber- Volume and Tow- Morphology Varia:ons X- ray CT, Microscopy, and LEROY (3D Automated Serial Sec*oning) 8

9 Tow-Level Material Property Variations (Task 1) Resin Cure Extent and Interphase Quan:fica:on Raman Spectroscopy, FTIR, Nanoindenta*on, Reference Peak Raman A1 A2 A3 Nanoindentation FTIR 9

10 Tow-Level Morphology Simulation (Task 2) Tow- level and es:mates of micro- scale varia:ons Virtual Tex*le Morphology Suite (VTMS) VTMS is a tex*le simula*on code that simulates the compac*on of fiber tows in a weave. It also has the capability of simula*ng micro- scale compac*on We will enhance its capability for hi- fidelity predic*ons of fiber volume & direc*ons within a tow Valida*on against data from Task 1 10

11 Tow-Level Morphology Simulation (Task 2) Virtual Tex:le Morphology Suite 11

12 Tow-Level Morphology Simulation (Task 2) Extract and compare Vf, tow shape, fiber direction (techniques in VTMS yet to be developed) 12

13 Multi-Scale Damage Sim./Quant. (Task 3) Simula:on Tool Development & Experimental Quan:fica:on Tow/Lamina- level homogenized proper*es from mul*- scale micro- level simula*on Homogenized proper*es include moduli and strength/fracture parameters. This builds on previous research efforts. 60% V f 13

14 Multi-Scale Damage Sim./Quant. (Task 3) Simula:on Tool Development & Experimental Quan:fica:on Discrete matrix damage evolu*on simula*on AFRL tool proven on laminates but needs extension to tex*le damage analysis. Experimental determina*on of damage via X- ray CT 14

15 Advanced Mixture Theory Dev./App. (Task 4) Effects of intra- tow/extra- tow interphase/interface on 3D tex:le processing/ residual stresses, damage and fa:gue Reference Peak Raman A1 A2 A3 FTIR Nanoindentation Effects of sizing diffusion/ reac:on, inhomogeneous cure Chemical shrinkage and CTE mismatches in cons:tuents Model (Hall): evolving interphase, chemothermal stresses depend on local fiber frac:on (x) Interphase/interface effects on individual filaments distributed within & near tows Orders of magnitude fa:gue life varia:on vs interphase (Subramanian, Reifsnider, S*nchcomb IJF (1995). 15

16 16 Advanced Mixture Theory Dev./App. (Task 4) β β β λ ψ ψ µ ψ D I F F T L + + = = A R N T e e M 1 ) ( Stress (on ) ( ) [ ] ( ) β β β µ θ η ψ ψ ψ λ N P A P v tr tr ) (,, 1, 1,,g g g g N g T e Ki e jk e Nj e g in r gr R g n M u n M F F F F u A I = = Interactive force (on ) Darcy s law Elastic strain gradient, stress Gradient of potential energy differences 1 1 ) (, ) (, = = = γ γ γ γ θγ θγ γ γ γ γ θ ψ n n e T e dn d d d U U N U U A F F P Change of thermal expansion Stress relative to initial configuration Change of chemical expansion Convected reaction rate Heat flow energy change Chemical potential Applicable across PMCs, CMCs, biomaterials etc: processing, chemical degrada:on, diffusion- reac:on with deforma:on and thermal effects N solids/liquids/gases

17 Potential Collaborations John s Hopkins Center of Excellence on Integrated Materials Modeling Jointly funded through AFOSR and RX Especially relevant for micro- scale damage evolu*on Nancy So^os UIUC fiber- tow interface/interphase property characteriza*on Arif Masud UIUC, K Rajagopal TAMU Leverages ongoing collabora*on, mul*scale computa*on & damage RXC (Structural Materials Division) internal projects Micro- structure sta*s*cal quan*fica*on (Craig Przybyla) Mike Uchic s work with LEROY 3D Automated Serial Sec*oning AFOSR funded Lab Tasks with RXCC Mul*- scale Modeling of Fracture Networks in Composite SubComponents (PM - Fariba Fahroo) 17

18 Questions 18