An integrated approach toward digital design and structural integrity analysis of out-of-autoclave composites under fatigue loading

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Fiber reinforced polymer (FRPs) composite materials have gained significant attention in high-performance applications owing to their high specific strength and stiffness benefits. To date, there are no available design tools that can efficiently and accurately predict the fatigue and in-service failure behavior of composite materials based on actual manufacturing conditions. For this reason, current use of composites is based on extensive, lengthy and costly testing which result in significant delays in introducing new composites into the market and their deployment in high-performance applications. The availability of such design tools is urgently needed today with increasing market demands for high-performance composites and the accompanying need for cost-effective and more agile approaches to composite manufacturing to meet those demands. The research will focus on Out-of-Autoclave (OOA) processing of FRPs as an alternative to the traditional high-pressure autoclave curing process commonly used for composites manufacturing. OOA technology enables composites to be produced using only vacuum pressures. These techniques have gained increased attraction in high performance industries. This is because despite autoclave processing advantages in producing high-quality products, it requires a much larger capital investment, complicated maintenance, higher temperatures and cure cycles times. The economic advantages to produce composites at lower cost with the OOA processing increases the utilization of composite components in industries such as aerospace, automotive, marine, wind turbines and leverage their advantages in reducing GHG emissions. However, compared to traditional autoclave components, OOA processing results in additional challenges in part quality control and defect formation, especially uncertainties in part thickness, fiber misalignments, and most importantly voids. The objective of this work is to develop an integrated modelling framework linking the manufacturing of OOA composites and inherent induced defects to the final composite's performance (process-structure-property relationship) under static and fatigue loading. This will facilitate the efficient design of OOA composites and enable the assessment of their structural integrity, and hence will accelerate their integration into industrial applications. 4 HQP (2MASc and 2 PhD) will undertake the proposed research program. The trained HQP will gain expertise in composites manufacturing, characterization and testing methods, damage monitoring, Finite Element modelling, coding and scripting. The HQP will also develop key interdisciplinary skills such as technical writing, presentation, and public speaking skills. Being a part of the Composites Research Network (CRN), HQP will have the unique opportunity to collaborate, and network with world-leading composites industries (e.g. Toray, Boeing, and others) leveraging the CRN's long-standing industrial collaborations.