Linking the scales towards non-conventional polymer composite structures

Introduction

The reduction of the environmental footprint of aviation relies on the development and fast deployment of lighter and more efficient polymer composite structures. However, the current configurations of composite aerospace structures result in a highly constrained design space.

Limitations of Current Methods

Additionally, the limitations of the state-of-the-art analysis methods result in overly conservative designs and in time-consuming certification methodologies. As a result, composite laminates have only contributed to modest weight savings in aircraft structures.

Project Objective

Based on these observations, the main objective of the project is to unleash the full potential of composite systems to yield more efficient aerospace composite structures. The premise is that polymer composite laminates are far from being used to their full potential, and that significant performance improvements of composite aerospace structures can be obtained by developing a new systems-thinking methodology that will link the different scales of a composite system.

Methodology

The methodology relies on the combination of new experimental studies, conducted at the micro-scale of the composite material, that will guide the development of analysis methods at different spatial scales.

Theoretical Developments

The theoretical developments, guided by experiments and computations, will create the building blocks of a neural network that will unravel the currently hidden relations between:

• Manufacturing conditions
• Micro- and meso-structures of a composite material
• Performance of a composite structure

Expected Outcomes

Overcoming this knowledge gap will enable the development of new, non-conventional micro-structures using different types of reinforcing fibres, and of new laminate configurations that will not be restrained by a limited set of fibre orientation angles.

It is expected that, for the first time, the discontinuity between material design and structural design will be removed, opening new avenues for concurrent optimization of composite materials and structures.