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

纤维增强聚合物（frp）复合材料由于具有高比强度和刚度的优点，在高性能应用中得到了广泛的关注。到目前为止，还没有一种设计工具能够基于实际制造条件高效、准确地预测复合材料的疲劳和使用失效行为。由于这个原因，目前复合材料的使用是基于广泛、漫长和昂贵的测试，这导致了将新复合材料引入市场和在高性能应用中部署的严重延迟。随着市场对高性能复合材料的需求不断增加，以及对复合材料制造的成本效益和更灵活的方法的需求，迫切需要这种设计工具的可用性。该研究将重点放在frp的非高压釜（OOA）加工上，作为传统高压高压釜固化工艺的替代方案，该工艺通常用于复合材料制造。OOA技术可以在真空压力下生产复合材料。这些技术在高性能行业中获得了越来越大的吸引力。这是因为尽管高压灭菌器在生产高质量产品方面具有优势，但它需要更大的资本投资，复杂的维护，更高的温度和固化周期时间。OOA加工以较低成本生产复合材料的经济优势增加了复合材料组件在航空航天、汽车、船舶、风力涡轮机等行业的利用率，并利用其在减少温室气体排放方面的优势。然而，与传统的高压灭菌器组件相比，OOA加工在零件质量控制和缺陷形成方面带来了额外的挑战，特别是零件厚度的不确定性，纤维错位，最重要的是空隙。这项工作的目标是开发一个集成的建模框架，将OOA复合材料的制造和固有的诱导缺陷与最终复合材料在静态和疲劳载荷下的性能（工艺-结构-性能关系）联系起来。这将促进OOA复合材料的有效设计，并使其结构完整性评估成为可能，从而将加速其集成到工业应用中。4名HQP（2名masc和2名博士）将承担拟议的研究计划。经过培训的HQP将获得复合材料制造、表征和测试方法、损伤监测、有限元建模、编码和脚本等方面的专业知识。HQP还将培养关键的跨学科技能，如技术写作、演示和公开演讲技能。作为复合材料研究网络（CRN）的一部分，HQP将有独特的机会与世界领先的复合材料行业（如东丽、波音等）合作，利用CRN长期的工业合作。

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.