Stargel - Multi-Scale

AFOSR
Multi-Scale Structural
Mechanics and Prognosis
18 March 2011
Dr. David Stargel
Program Manager
AFOSR/RSA
Air Force Office of Scientific Research
Distribution A: Approved for public release; distribution is unlimited. 88ABW-2011-0794
Structural Mechanics
Thrusts
Novel Flight Structures
• Morphing Aircraft
• Flapping Wing Air Vehicles
• Non-traditional Structural Configurations
Making Today’s
ISHM Technology Obsolete Untested
Flight
System
• Structural Health Monitoring

• Non-destructive Evaluation
• Thermo-acoustic Response
• Prognostics
• Space Structures
• Physics-based Modeling
• Penetration Mechanics
Multi-scale Modeling and Prognosis Structural Dynamics 2
Challenges
Novel Flight Structures
• Multi-disciplinary Design Problems
• Non-traditional Structural Configurations
• Student Education
ISHM Untested
Flight
System
• Uncertainty/Variability
• Probability of Detection
• Computation Cost
• Verification & Validation
• Non-linear Interactions
• Time & Length Scale Couplings
• Testing Environments
Multi-scale Modeling and Prognosis Structural Dynamics 3
Novel Flight Structures:
Fundamental Research Trends
• “Disruptive” new flight structures concepts and unprecedented
flight configurations
• Reconfigurable adaptive flight structures with on-demand shape
morphing for real-time responce to changing missions demands
and threats
• Hybrid flight structures of dissimilar materials (metallic,
composite, ceramic acting together) under dynamic loads, blast,
and sustained extreme environments:
– Ceramic matrix composites
– Multi-material joints and/or interfaces
• Conventional strength-based analysis of metallic structures (TR)
• Multi-scale predictive modeling for combined design of
structures and materials
4
Structural Dynamics:
• Control of dynamic response of extremely flexible nonlinear flight

structures
• Modeling of unsteady energy flow in nonlinear flight structures at
various flight regimes
• Nonlinear dynamics of thin-wall structures of functionally-graded
hybrid materials with internal vascular networks under extreme
thermo-acoustic loading conditions
• Classical modal analysis and linear vibration control (TR)
• Nonlinear structural dynamics in interaction with air flow, unsteady
heating, directed energy, servo-controls at various regimes
• New modeling methods for guided wave propagation and nonlinear
vibrations (e.g., spectral finite elements; peridynamics; etc.)
5
Multi-scale modeling and prognosis:
• Stochastic prediction of the structural flaws distribution and
service-induced damage on each aircraft and at fleet level
• Probabilistic analysis that accounts for variability due to
materials, processing, fabrication, maintenance actions,
changing mission profiles typical of Air Force applications
• Conventional fatigue analysis of metallic structures for fixed-
life structural design/prognosis
• On-board health monitoring and embedded NDE of flight
structures: unprecedented sensing methods; compact
structures and material prognosis algorithms
• Prediction of flight structures “hot spots” prone to early in-
service failure and/or degradation
• Prognosis of advanced structures: simultaneous SHM/NDE
and analysis of the interacting material and structural
behaviors under long-term in-service conditions
6
Structural Mechanics Vision of
Future Weapon Systems
Past Present Future
Few tests represent

aircraft fleet Each aircraft has its
CAE supplements own virtual twin
experimental fleet models
7
Collaborations
• NASA - Ed Glaessgen/Steve Smith
• ARO/ARL - David Stepp/Jim Chang
• ONR - Ignacio Perez/Liming Salvino/David Shifler
• NSF - Glaucio Paulino
• DTRA – Su Peiris
• MURI on Uncertainty – Fariba Fahroo
• Mathematics for Multi-Scale
Modeling – Fariba Fahroo
• RB/RX Collaborative Lab Task –
Ravi Chona/Tom Eason/Reji John
• MURI on Hybrid Structures –

Joycelyn Harrison/Ali Sayir
8
AFOSR/NASA Space Act Agreement
9
Excerpt from NASA Roadmap –
A Transition
Future
Each aircraft has its

own virtual twin
10
11
Multi-Scale Simulation for Structural Reliability
AFOSR RB-RX Collaborative Lab Task: Proposal Plan
AFOSR Program: Multi-scale Structural Mechanics
Program Manager: Dr. David Stargel
28 January 2011
PIs: Ravi Chona*, Tom Eason* and Reji John**

Air Force Research Laboratory, AFRL
*Air Vehicles Directorate, **Materials & Manufacturing Directorate
Wright-Patterson Air Force Base, OH, 45433
Scientific Challenge and Impact
How can material-level damage evolution & accumulation best

inform structural-level reliability assessment … and vice versa?
Needed: A framework for propagating information across length scales

drilling down only as far as absolutely necessary
nano micro meso macro

Secondary images
Fracture surface
Essential to realizing the Digital Twin vision

Long-Term Goal and Objectives
• Goal
– Identify and optimize the linkage of robust models having the
appropriate volume element dimension to predict location
specific properties as a function of temperature, environment,
stress and time
• Objectives
– Explore the sensitivity of structural airframe component models
to the multiscale elements focused on the microscale structural
degradation mechanism
– Identify optimized triggering mechanisms leading to the
appropriate high fidelity model without drilling down to the
atomistic level (unless absolutely necessary)
– Demonstrate feasibility of approach and computational results
via experimental validation
• FY17 - Simulate variability in structural scale predictions due to material scale
uncertainties
Accomplishments
FY09-FY10-FY11
A visco-plastic-damage mechanics model
incorporating the effects of oxygen concentration:
• Initiated development of a multiscale computational
framework (Variational Multi-scale Enrichment method)
– Efficient enrichment of structural scale simulations with
information from grain scale (micro-scale) simulations
• Characterized Oxygen enriched region in Ti-6242S at
anticipated use temperatures
– Up to 650°C (1200°F), 420 hours
– Limited data available in this range
• Developed 1D diffusion microstructure-sensitive model
incorporating partial O2 & temperature = f(time)
• Developed 2D microstructure-based finite element
diffusion analysis
– Actual microstructure from high resolution backscattered
image; Grain geometry represented explicitly in 2D
• Developed model to relate critical strain to onset of
widespread cracking under tensile loading
Next (Bridging) Steps
• FY12
– Integrate Oxygen ingress and tensile cracking models into the
Variational Multi-scale Enrichment (VME) method
– Validate ability to predict Oxygen ingress effects at micro and meso
scales
– Initiate development of a coupled isothermal crystal plasticity – oxygen
transport model
– Initiate investigation of effects of non-monotonic, repetitive loading on
Oxygen ingress induced damage
– Develop detailed research work plan for Way Forward
• FY17
– Simulate variability in structural scale predictions due to material scale
uncertainties
– Conduct full-scale structural validation
Synthesis, Characterization and Prognostic
Modeling of Functionally Graded Hybrid
Composites for Extreme Environments
Principal Investigator
Dimitris C. Lagoudas
Department of Aerospace Engineering
Texas A&M University
College Station, TX 77843
Partner Universities
Texas A&M University
University of Illinois at Urbana-Champaign
Virginia Polytechnic Institute and State University
Stanford University
University of Dayton Research Institute
http://muri18.tamu.edu
AFOSR-MURI
Functionally Graded Hybrid Composites
17
Goals
A comprehensive research program coupling thermal-

acoustic-mechanical flight loads to guide the design of
multi-functional Functionally Graded Hybrid Composite
(FGHC) systems with integrated sensing capabilities for
extreme environments.
 multi-scale simulations
 multi-scale characterization
Target operating environment: 250 °C - 1000 °C, with a durability

envelope of 1000 hours exposure at 550 °C and 300 thermal
cycles
AFOSR-MURI
18
Mn+1AXn Phases (n = 1, 2 and 3)
Easy to form and machine

Stiff (320 GPa) and tough
Good thermal and electrical conductor
Thermal shock and fatigue resistant
Oxidation resistant (in air up to 1400°C).
Low friction
211 312 413
AFOSR-MURI
Fundamentals of FGHC
Multi-scale
Characterization
Fabrication 1000C
Joining PMC
GCMeC w/ GCMeC,
embedded • Initial material
300-400C SHM sensors parameters
Structural • Validation
PMC Health
experiments
Monitoring
Multiscale Structural
Modelling
AFOSR-MURI
Research Thrusts
Development and Fabrication Develop multifunctional FGHC
with multiple layers: a ceramic thermal barrier layer, a graded ceramic/metal
composite (GCMeC) layer and a high-temperature polymer matrix composite
(PMC) layer.
Multi-scale Characterization Develop and apply experimental

techniques to obtain mechanical andphysical properties of GCMeC and PMC
layers and of the hybrid interfaces.
Insitu NDE/SHM Integrate of SHM capabilities through networked

sensor/actuator arrays,diagnostic algorithm development, control theory and
fabrication optimization.
Multi-scale Modeling Develop of novel material systems for use in

extreme environments: design FGHC microstructure, develop experiments
and interpret data to obtain basic material properties.
AFOSR-MURI
21
Exciting New Initiatives
Transformation Computing in
Aerospace Science & Engineering
(T–CASE)
Today, 2011
Tomorrow, 2015
Future, 2025… • To create transformational approaches in

computing for aerospace science and
engineering
 Novel micro-architectures?
 Hybrid/complementary
• Multi-disciplinary approach including novel
photonic methods? computer architectures, system software, and
 Quantum-based systems? mathematical algorithms
 Bio-computing? • Emphasis on
 Neuro-morphic computing? • Multi-scale modeling & structural
mechanics
• Complex flow physics modeling & control
PMs: David Stargel & Douglas Smith
Structural Mechanics Summary
Past Present Future
• Three
Few tests
corerepresent
thrusts with the integrating vision of a
aircraft fleet Each aircraft has its
Virtual Twin Concept
own virtual twin
•Vision is expanding acrossCAE supplements
other organizations
experimental fleet models
• Program is coordinated and actively collaborating

with other government agencies and within AFOSR
• Joint Roadmap Development with NASA
• Exploring new transformational capabilities
• AFOSR is leading the way
• Questions??
25
BACKUP CHARTS
Initial Approach
Define needed framework by identifying critical elements and the

interplay of sensitivity and triggering mechanisms
• Explore the incorporation of • Understand the role of

time and location specific microstructure variation
properties on component life
via modeling
• Develop damage evolution
physics and short crack growth
• Investigate refining life initiation and growth
models using reasonable understanding via the use of
multi-scale feedback / limited laboratory sub-scale
communication approaches coupon tests
• Validate results via sub-scale • Enable subscale model feedback
laboratory structural testing mechanism from macroscopic
model
Demonstrate this framework using a metallic system (Ti-6242S)

subjected to thermal-mechanical fatigue
The Way Forward
• FY13
– Develop a coupled isothermal crystal plasticity – oxygen transport model that
accounts for different phases (alpha, beta, grain boundary) and temperature
cycle effects
• FY14
– Incorporate geometric nonlinearity into the Variational Multi-scale Enrichment
(VME) framework and implement highly-parallelizable computational strategies
– Understand effects of fatigue loading, tension vs. compression, partial O2
pressure on oxygen ingress
• FY15
– Conduct structural scale isothermal validation
– Implement adaptive VME approach to track critical oxygen concentration front
– Develop 3D microstructure-based diffusion model
– Develop mechanistic model to predict remaining ductility and life
• FY16
– Conduct structural scale thermal-mechanical fatigue validation
– Add field discontinuities (e.g., cracks) to VME framework
– Enhance oxygen ingress model to account for thermal cycles, gradients, stress
level, and presence of damage
• FY17
– Simulate variability in structural scale predictions due to material scale
uncertainties
– Conduct full-scale structural validation
Multi-scale Characterization
nm
CHARACTERIZATION OF COMPOSITE LAYERS

mm
Graded Ceramic/Metal Matrix Composites
Polymer/Matrix Composites
Local Strain Fields/Damage Initiation
INTERFACES AND BONDED JOINTS

Thermal Impedance mm
Interfacial Delamination
STRUCTURAL PERFORMANCE
Impact Response cm
Vibration Analysis
AFOSR-MURI
29
High Temperature SHM/NDE
In-situ characterization of the integrity of FGHC
Sensors & Sensing Network
Diagnostic Algorithms
Modeling
Integration & Characterization
AFOSR-MURI
Multi-scale Modeling
Wide Range of Scales
Predict performance of material & components
Develop strategies for joining parts
Expedite mechanical & thermal design
Define in-flight mechanical & thermal loads
AFOSR-MURI
SPARK PLASMA SINTERING SYSTEM
Impact on the MURI project:
• Rapid synthesis of GCMeC;

• Better control of phase distribution in GCMeC;
• Lowering the co-sintering temperature of GCMeC;
Ti2AlC-TiAl composite • Gradual phase transition in GCMeC;
fabricated by SPS1.
• Homogeneous and fully dense GCMeC;
• SPS has been proven to be successful technique for
co-sintering composites and functionally graded
composites with MAX phases.
Ti2AlC-TiAl composite
fabricated by SPS2.
1Y. M. Luo, P. Wei, S. Q. Li, R. G. Wang, J. Q. Li, Materials Science and Engineering A, 2003, 345, 99.
2 B. Mei, o. Y. Miya, Materials Chemistry and Physics 2002, 75, 291.
AFOSR-MURI
MATERIALS
Ceramic MAX Phase Metal Composites
GCMeC
Ti2AlC
Ti – Ti2AlC
Ni50Ti50 - Ti3SiC2(Ti2AlC)
PROCESSING & CHARACTERIZATION
Karaman, Radovic, Lagoudas
MODELING Lagoudas, Whitcomb, Gao, Reddy, Ochoa
AFOSR-MURI
Mn+1AXn Phases (n = 1, 2 and 3)
Easy to form and machine

Stiff (320 GPa) and tough
Good thermal and electrical conductor
Thermal shock and fatigue resistant
Oxidation resistant (in air up to 1400°C).
Low friction
211 312 413
AFOSR-MURI
Sintering of Ti2AlC Ceramics
Porosity of Ti2AlC samples after sintering at
1400°C for 4 hrs Under 96% H2, 4%Ar
Powder Mixing Porosity due to pressure-less sintering
Cold Pressing
Sintering at
1400 OC – 4 hrs
Sintered Ti2AlC
AFOSR-MURI
Oxidation of Ti2AlC
Oxidation kinetics of the self-healing protective oxide on ceramic
1400 1500
Oxide Surface Oxide layer after slight surface

1200 grinding
1200
1000
Oxide Layer
Intensity (a.u.)
Intensity (a.u.)
900
800
2500 2500
Ti2AlC 600
TiO
TiO22
Ti 3AlC2
Ti3AlC2
TiO
TiO22
Ti 3AlC2
Ti3AlC2
600
Ti 2AlC
Ti2AlC Ti 2AlC
Ti2AlC
Oxidation in air 2000

400
2000 TiC
TiC
Al 2O3
Al2O3
TiC
TiC
Al 2O3
Al2O3
1200°C 72 hrs 300
Intensity (a.u.)
1500
Intensity (a.u.)
1500 200
EDS Map 1000

0 1000 0
20 30 40 50 60 20 30 40 50 60
Al 2Theta 2Theta
500
C 500
XRD and EDS analysis on the oxidized surfaces

O show formation
0 of mainly protective Al2O3 with
0
Ti 20 some40 traces
30
20 30
50 on 60
TiO2 on
40 50 60
the surface, which
2Theta
2Theta
subsequently controls further oxidation
AFOSR-MURI
Graded Ti – Ti2AlC Composite
500 mm
100% Ti 100% Ti2AlC
Sintered at
1000OC for
4 hours
* The color figure is optical

image, and the grayscale
figures are BSE
AFOSR-MURI
Processing Porous MAX Phase
Preforms
Ti2AlC-35%
Porous
Disadvantages of processing porous MAX

samples without pore formers:
• Small pore size.

• Low green body strength of the samples
sintered at lower temperatures.
AFOSR-MURI
Highly Reflective TBC
of Nano-Porous Aluminum Oxide
High radiative and convective heat flux on high speed airplane structures
Thermal barrier coating (TBC) with high reflectivity and low thermal
conductivity protects the base structure
Multi-layer coating to increase

reflectivity TBC
Bow shock
Incident
Absorption
radiation
Thermally grown oxide

Emission and reflection Transmission
x
Bond coat
Supersonic Functionally
Ceramic
flow graded material
Reflection and coating
emission
Thermal Blunt body

M∞ Convection Conduction
radiation from
hot gas
AFOSR-MURI
Ni50Ti50 - Ti3SiC2 or Ti2AlC Composite
controlling the interface thickness
Ni50Ti50
Ni50Ti50
Interface ~20 mm Interface ~50 mm
Ti₃SiC₂
Ti₃SiC₂
7 4 20
19
16
15
13
Hardness
10 10 7
5
(GPa)
5 4
8 0
Interface ~20 mm Ti3SiC2

1
Interface 2
9 6 NiTi
3
Ti2AlC
AFOSR-MURI
MATERIALS
High Temperature
Polymer Matrix Composites
Polyimid Based
Actively Cooled

Ounaies, Sottos, White
MODELING
Geubelle, Ochoa
AFOSR-MURI
Ti-Polyimide Adhesion
 Joining GCMeC and PMC: Focus on Titanium and
Polyimide as a first step
In order to achieve favorable adhesion the following parameters
are investigated with SLS tests
 Cure cycle of polyimide
 Surface treatment of Ti
Overlap Length =
Substrate 1” (2.54mm)
Thickness =
0.063” (1.6mm) Adhesive Thickness =
10-30 μm
Substrate Length = 4” (100.16mm)
AFOSR-MURI
Curing Effect on SLS Results
2000
1800
1600
Cure Cycle Max Load /
1400 Area
1200 Standard 409.4 psi
Force (N)
1000 Standard Cure - B Short B-Stage 334.4 psi

5 hour) D
800
12 hour) A Long B-Stage 254.6 psi
600
400
200
0
0.000 0.050 0.100 0.150 0.200 0.250
Displacement (mm)
•Standard cure was chosen as curing method.

•B-Stage cure can be used to minimize thermal residual stresses.
AFOSR-MURI
Etching Effect on SLS Results
The acid etching increased the maximum tensile force

that an SLS sample could sustain before failing.
4500 1000
4000 900
Average Max Stress (psi)

3500 800
3000 700
Force (N)
2500 600
0 min. Acid Etch 500
2000
1500 30 min. Acid 400
Etch
1000 1 hour Acid Etch 300
500 200
0 100
0.000 0.100 0.200 0.300 0.400 0.500 0.600 0
Displacement (mm) 0 minutes 30 minutes 1 hour 6 hour
AFOSR-MURI
Concept of Active Cooling
AC-PMC
 Sacrificial fibers in red integrated within the 3D preform weave

are removed during post-cure to form microvascular networks
 Active cooling is provided by coolant flow through embedded
network
AFOSR-MURI
Development of SF Prototypes
Embedding Fibers Curing Process Fiber Evacuation
Evacuated Microchannel
1-D Specimen Mold Material System
EPON 828/EPIKURE 300
Ratio { 100 : 22.7 }
Solid Fiber
100% Evacuation
2-D Specimen Mold Room temperature
curing for 24 hours
followed by curing for
90 mins at 82°C and
90 mins at 150°C Shell Wall of Evacuated
Microchannel
1-D and 2-D molds for Fiber evacuation by two step
heating at 220°C (12 hrs) and
embedding sacrificial fibers 250°C (2 hrs) in vacuum
Chloroform can clean residue in the channels
AFOSR-MURI
3-D Woven Composite Prototype
with embedded microchannels
a) 3-D woven glass fiber mat containing sacrificial PLA fibers (pink)
a) Optical image of evacuated microchannels partially filled with

fluid (blue) (scale bar = 5 mm)
a) MicroCT image showing 3D microstructure of embedded

microchannels in a 3D woven composite (scale bar = 10 mm)
AFOSR-MURI
Design of Micro channels
 Analysis Tools conduction convection
 FEM Solution +
. q
m
→
 Genetic Algorithms (NSGA-II)
Constraint: Objective functions: Analysis Options:
 Connected networks  Maximum solid temperature  Constant inflow rate

 Void volume fraction
 Fluid temperature  Constant power
 Pressure drop
Constant inflow rate

design sample
Constant power
design sample
AFOSR-MURI
Impact of Cooling
AFOSR-MURI
FUNCTIONAL INTEGRATION
SHM Network
Sensors
Interfaces
Chang, Lafdi, Lagoudas, Seidel,
MODELING
Chang, Lagoudas, Ochoa, Seidel, Whitcomb
AFOSR-MURI
High Temp In-Situ SHM/NDE
Develop a sensor network that can be fabricated at the micro-scale
and be expanded to the macro-scale and that can stand working
temperatures up to 1000C
- +
+ - +- +
 Development of high temperature sensors and sensor networks (maximum

temperature 1000°C)
 Manufacturing of hybrid composites (IM7 or IM6) integrated with our sensor

network (maximum temperatures 300°C)
 Diagnostics
AFOSR-MURI
Diagnostics
PZT
Adhesive layer Input Signal Simulation Output Signal
Modeling of PZT and adhesive layer Wave propagation simulation using

SEM
Future steps: Test panels to examine signals at elevated temperatures (below

maximum temperature that the network can stand)
AFOSR-MURI
Developing HT Sensors
With proper tolerance factors, perovskite structures around

morphortropic phase boundary can exhibit both high Tc and high
piezoelectric properties.
 (1-x) BiScO3 – x PbTiO3 (x~0.63), which has a relatively high

piezoelectric coefficient and high thermal depoling resistance, can be a
good candidate for the SHM sensor network.
 Use screen printer to fabricate thin (10~100 μm) BSPT high Tc

piezoelectric sensors
 Control the grains/domains of these thin BSPT sensors
AFOSR-MURI
High Piezoelectric Effect :
Perovskite Structure
ABO3
(1-x) ABO3-(x) PbTiO3 O B
Another morphortropic
phase boundary (MPB) A
Perovskite Tolerance Factor

of ABO3:
Perovskite structures with composition

around MPB exhibit high piezoelectric
properties!
ri : ionic radius of atom i
AFOSR-MURI
Thermal Depoling Test
Fabricated ultrasonic sensors BS-PT (x=0.63) and compared with PZT.
All samples were measured at room temperature after a 2-hour exposure at specific
set temperatures.
AFOSR-MURI
CNT Based Fuzzy Interface
Aligned CNT
Curly CNT
Ceramics
Metal
6mm
SHM
Composite
Fuzzy Fiber
AFOSR-MURI
Sensor Development: Fuzzy Fiber
Conductivity changes
Strain, damage
CVD CNT grown on

glass & carbon fiber
CNT
include viscoelastic effects and
damping frequency response
AFOSR-MURI
Wedge RVE for Glass-CNT Fiber
Obtain effective properties
to compare with those
acquired by multi-layer
composite cylinder method.
wedge of the full volume
apply a combination of
periodic and symmetry
boundary conditions
AFOSR-MURI
CNT on T650-8H Fabric Layer
Fracture Toughness
Fabricated laminates
with fuzzy midplane
Conducted DCB tests
Improvement is 2X
over traditional (w/o FF)
AFOSR-MURI
CNT grown on Ti
AFOSR-MURI
CNT - Thermal Impedance
Study the effect of thermal contact resistance on heat transfer
capability and the effectiveness of CNT as thermal interface materials.
CVD on quartz-- aligned CNTs with

thickness ranging from several micrometers
to about 200 um with a narrow diameter
distribution around 10 nm
AFOSR-MURI
Damping & Modulus of Ti2AlC
Oberst Beam Method
Determined material and

damping properties of Ti2AIC on
an Al substrate
(ASTM Standard E756-05)
estimated static Young’s

modulus of 5.52 GPa
 loss factor of 0.0349
Almost doubles the damping
AFOSR-MURI
62
MULTI-SCALE
STRUCTURAL RESPONSE
CHARACTERIZATION
Goulbourne, Inman, Lafdi, Ochoa, Lagoudas
MODELING
Inman, Whitcomb, Lagoudas, Reddy, Cizmas,
Ochoa
AFOSR-MURI
3-D X-ray Tomography & FEA
Study of failure of metal-ceramic composite with
detailed consideration of microstructure
 Obtain microstructure
images
 Porous NiTi
 GCMeC
Ti-Ti2AlC composite
 Translate into FE mesh (2D SEM image)
finite element analysis of

representative volume elements
of metal-ceramic composites
under tension, compression and
shear loading Porous SMA
(3D CT image)
AFOSR-MURI
Simulation of Ceramic Phase with SMA
450
Porous NiTi images were used as a base 400
 Pores changed to be ceramic content 350
300
 Some pores along the edges were not
Stress (MPa)
250
converted 200
 Mesh is created directly from image voxels 150

20:1 Small
15:1 Small
• Linear, 8-node elements
100
20:1 Large
50
15:1 Large
 Each voxel is 9.8μm 0
0 0.01 0.02 0.03 0.04 0.05 0.06
Strain ε (%)
AFOSR-MURI
Interpenetrating Phase Composite
MICROMECHANICS MODELS FOR GCMEC
 Employing a cubic RVE containing a tetrakaidecahedral cell or a 4-strut
reinforcing sub-unit:
1.82E+11
1.72E+11 Voigt
Reuss
1.62E+11 FEM-Unit cell
Effective Young's Modulus

FEM-Ey of four
 Using variational bounding theorems

strut model
1.52E+11 FEM-Ex of four
strut model
HS upper bound
1
modified micromechanics results and FEM 1.42E+11 HS lower bound

1
Tuchinskii upper
bound
Tuchinskii lower
 Validated by comparing with each other

1.32E+11 bound
shear lag model
1.22E+11
 Applied to al matrix with

1.12E+11
alumina reinforcing phase 0 0.05 0.1 0.15

Volume Fraction
0.2 0.25 0.3
AFOSR-MURI
Simpleware Mesh from
Synthesized μCT Data
Simpleware mesh using upcoming
mesh decimation algorithm
Synthesized μCT slices of plain

weave textile
Typical hex mesh

of plain weave unit cell
(in-house code)
AFOSR-MURI
Oxidation Progression through
Plain-Weave Composite
Goals
Prediction of oxidation progression
Precursor to predicting mechanical response of an
oxidized configuration
AFOSR-MURI
Integrated Multiscale FE Analysis
Material or structural redesign Integrally woven stringer-stiffened panel
Local failure
analysis
Microstructure
Macroscopic deformation Micromechanics

modes
Effective properties
Macro elements
Structural analysis
AFOSR-MURI
Impact Response of Novel Materials
SEM Image of
Ti2AlC
Fragment
AFOSR-MURI
Impact and DIC Measurements
shot_04 Impactor Contact Force Trace, Muzzle Velocity = 13.8566 m/s
Contact Force
Displacement
500 5
Contact Force (N)
Z Disp (mm)
0 0
2.5 3 3.5 4 4.5 5 5.5

time (s) -3
x 10
Force and displacement data during impact
via accelerometer [Impactor velocity: 14 m/s]
AFOSR-MURI
Impact Loading
Multilayer Polymer Plates
PC/TPU/PMMA samples were instrumented
with piezoelectric transducers, then
impacted at progressively increasing speeds
using gas gun. Impedance measurements
were taken before and after each impact
AFOSR-MURI
Measuring Damage from
Consistent Force Impacts Crack
Characteristics
Impact 1
8 m/s, cracking, no delamination
Number of Spars 4
Max Spar-Spar Length 0.8 "
Radial Diameter -
Impact 2
Number of Spars 5
8 m/s, cracking, delamination
Max Spar-Spar Length 0.8 "
Radial Diameter 0.137”
Impact 3
Successive 8 m/s, cracking and Number of Spars 5
Impacts delamination growth Max Spar-Spar Length 0.8 "
Radial Diameter 0.141"
Impact 4
Increasing Number of Spars 5
Damage Max Spar-Spar Length 0.9"

Radial Diameter 0.171"
AFOSR-MURI
High Order Finite Elements of
Spectral/hp Type
 Finite element approximation of variable u in two dimensions
m
ux , y   uhp x , y    ej j  ,  ˆe
in 
j 1
 Multi-dimensional interpolation functions constructed from tensor
products of 1-D Lagrange interpolation functions of spectral type
0.5
-0.5
-1 -0.5 0 0.5 1
AFOSR-MURI
Least-Squares Finite Element
Solution of FSI Problem
Results at t=0.25, 0.50 and 0.70 (a) velocity component vx (b) velocity component vy
AFOSR-MURI
Aerothermoelastic Response
Predict the structural stresses and deformations that functionally-graded
hybrid composite (FGHC) materials would be subjected to due to
aerodynamics, inertial and thermal loads.
Developed, verified and validated an efficient structural nonlinear beam

model that retains all cubic nonlinear terms
First eight frequencies of a 45 deg sweep wing

computed with Abaqus and the nonlinear beam model.
AFOSR-MURI
Collaborations In Place
 AFRL/RX Hybrids Branch Jeff Baur

 Benchmark IM7-BMI 5250 Panels for common tests
 Fiber Metal Laminates interface-joining study
 HT Polymer guidance
 AFRL/RB Vehicles Directorate Thomas Eason

 Structural –Thermal Loads
 Boeing Gail Hahn, Kay Blohowiak

 TiGr, HT Polymer-metal adhesion MOA signed
AFOSR-MURI
DURIP: ACQUISITION OF MECHANICALLY
ASSISTED SPARK PLASMA SINTERING SYSTEM
FOR ADVANCED RESEARCH AND EDUCATION ON
FUNCTIONALLY GRADED HYBRID MATERIALS
Investigators:
Dimitris Lagoudas, Aerospace Engineering, Texas A&M University
Miladin Radovic, Mechanical Engineering, Texas A&M University
Ibrahim Karaman, Mechanical Engineering, Texas A&M University
Zoubeida Ounaies, Aerospace Engineering, Texas A&M University
AFOSR-MURI
The spark plasma sintering (SPS) is a low pressure
sintering method . During the process, electrical
energy pulses is applied to the gaps between powder
materials and effectively utilizes the high energy of
the spark plasma generated momentarily between
powder particles by spark discharges to achieve
thermal and field diffusion. The pulsed current causes
melting and evaporation of surface of powder
particles without heating the particle interior.
Advantages:
- Better control of microstructure and grain growth
rate while obtaining a near theoretical density than
other sintering techniques.
- Sintering time is very short, in the order of few
seconds.
- Lower sintering temperature!
AFOSR-MURI
Impact on the MURI project:
• Rapid synthesis of GCMeC;

• Better control of phase distribution in GCMeC;
• Lowering the co-sintering temperature of GCMeC;
Ti2AlC-TiAl composite • Gradual phase transition in GCMeC;
fabricated by SPS1.
• Homogeneous and fully dense GCMeC;
• SPS has been proven to be successful technique for
co-sintering composites and functionally graded
composites with MAX phases.
Ti2AlC-TiAl composite
fabricated by SPS2.
1Y. M. Luo, P. Wei, S. Q. Li, R. G. Wang, J. Q. Li, Materials Science and Engineering A, 2003, 345, 99.
2 B. Mei, o. Y. Miya, Materials Chemistry and Physics 2002, 75, 291.
AFOSR-MURI
Current status:
• Negotiations with 3 major SPS

manufactures are finished;
• Texas A&M provided adequate space –
plans for infrastructure needed for SPS in
progress.
• Expected installation – 6-7 months after
funds become available.
AFOSR-MURI
THANK YOU!
AFOSR-MURI

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AFOSR

• Structural Health Monitoring

• Control of dynamic response of extremely flexible nonlinear flight

Few tests represent

• MURI on Hybrid Structures –

Each aircraft has its

PIs: Ravi Chona*, Tom Eason* and Reji John**

How can material-level damage evolution & accumulation best

Needed: A framework for propagating information across length scales

nano micro meso macro

Essential to realizing the Digital Twin vision

A comprehensive research program coupling thermal-

Target operating environment: 250 °C - 1000 °C, with a durability

Easy to form and machine

Multi-scale Characterization Develop and apply experimental

Insitu NDE/SHM Integrate of SHM capabilities through networked

Multi-scale Modeling Develop of novel material systems for use in

Future, 2025… • To create transformational approaches in

• Program is coordinated and actively collaborating

• Exploring new transformational capabilities

• AFOSR is leading the way

Define needed framework by identifying critical elements and the

• Explore the incorporation of • Understand the role of

Demonstrate this framework using a metallic system (Ti-6242S)

CHARACTERIZATION OF COMPOSITE LAYERS

INTERFACES AND BONDED JOINTS

In-situ characterization of the integrity of FGHC

Sensors & Sensing Network

Integration & Characterization

Predict performance of material & components

Develop strategies for joining parts

Expedite mechanical & thermal design

Define in-flight mechanical & thermal loads

Impact on the MURI project:

• Rapid synthesis of GCMeC;

MODELING Lagoudas, Whitcomb, Gao, Reddy, Ochoa

Easy to form and machine

Powder Mixing Porosity due to pressure-less sintering

Oxide Surface Oxide layer after slight surface

Oxidation in air 2000

1200°C 72 hrs 300

EDS Map 1000

XRD and EDS analysis on the oxidized surfaces

* The color figure is optical

Disadvantages of processing porous MAX

• Small pore size.

Multi-layer coating to increase

Thermally grown oxide

Thermal Blunt body

Interface ~20 mm Ti3SiC2

PROCESSING & CHARACTERIZATION

1000 Standard Cure - B Short B-Stage 334.4 psi

•Standard cure was chosen as curing method.

The acid etching increased the maximum tensile force

Average Max Stress (psi)

 Sacrificial fibers in red integrated within the 3D preform weave

a) Optical image of evacuated microchannels partially filled with

a) MicroCT image showing 3D microstructure of embedded

Constraint: Objective functions: Analysis Options:

 Connected networks  Maximum solid temperature  Constant inflow rate

Constant inflow rate

 Development of high temperature sensors and sensor networks (maximum

PIs: Ravi Chona, Tom Eason and Reji John**