Experimentally validated physics-based multi-scale models for long-term durability assessment of next-generation lightweight composite vehicles

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For decades transportation vehicles have utilized polymer matrix composite (PMC) materials for secondary structural components, including aircraft aerodynamic fairings and interior automobile panels, due to their high strength and low weight when compared to metallic alloys. Only in recent years have they been utilized for primary structures, which stems from economic and societal concerns pressuring manufacturers to develop lighter fuel-efficient vehicles. Consequently, the long-term reliability of PMCs is now highly important, in particular for components with fatigue critical performance indicators such as automobile chassis side beams and aircraft wing spars. However, there exists a major scientific gap for addressing their performance under complex loading conditions.*** Currently, design tools for assessing the long-term behaviour of PMC structures are unavailable, where instead designers use inaccurate empirical failure theories. The resulting drawback is twofold: (i) designs are conservative and suboptimal, and (ii) manufacturers require extensive and costly test programs to certify new products. Since the 10-year forecast for lightweight PMC usage in transportation vehicles is an expected growth by 50% to meet drastic fuel efficiency targets, it is imperative to address these major issues. The proposed research program aims to generate a knowledge base for lightweight PMCs, and develop design tools for their long-term assessment in order to minimize the weight of next-generation composite vehicles. Through an experimental test program the multiaxial cyclic behaviour and failure processes of PMCs will be characterized, enabling the development of a physically-based multi-scale simulation platform for assessing their performance under repeated loading conditions. The long-term objective is to efficiently design and certify next-generation lightweight composite vehicles by integrating the model into the product design process. This work will redefine the understanding and usage of lightweight PMC materials for fatigue critical applications in transportation vehicles.*** This is the first study to consider multi-scale damage-based fatigue tools for the design of composite structures. With drastic fuel efficiency targets currently set by manufacturers, this ensures that the proposed research is timed correctly to develop the knowledge-base and enable technology required to better design next-generation lightweight composite vehicles, which are expected to be market-ready in the next decade. The innovative advancements made will increase the safety of vehicles and decrease development costs, allowing Canadian industry partners to stay competitive. New lightweight fuel-efficient vehicles will lead to reduced environmental impact, helping Canada gain global leadership in green technology, and reduce operating costs for end users of these products.**