VIVA: A Software Toolkit for Automated Multiscale In-Situ Effective Mechanical Property Prediction from Computed Tomography of As-Built Composites

ATA Engineering, Inc., (ATA), in collaboration with the National Institute for Aviation Research (NIAR) at Wichita State University, proposes to develop Volume Image-based Virtualization for Allowables (VIVA), a software toolkit for the automated physics-based prediction of multiscale in-situ effective mechanical properties of as-built laminated composites reconstructed numerically from X-ray computed tomography (CT) data. The toolkit takes a multistage approach to property generation, starting with a state-of-the-art rule-based and data-driven machine learning-based image segmentation procedure to generate multiscale sub-surface geometric models from input CT data that include laminate structure features, such as ply waviness, orientation, interfaces, and drops, and critical defects, such as ply wrinkles, voids, and resin-rich regions. Multi-fidelity finite element (FE) models will then be created, resulting in the generation of a set of multiscale as-built representative volume element (RVE) models. Virtual characterization of the RVEs will generate a relationship between the material scales that is finally propagated through the component scale as a set of local mesoscale and global macroscale in-situ, nonlinear, anisotropic effective mechanical properties encompassing various hot/wet conditions and collectively supporting static, dynamic, and progressive damage analyses. In the Phase I Base, a prototype toolkit will be developed and demonstrated. The Option period will then prepare for verification and validation tests and software enhancements, including automated property assignment for different commercial FE types, that will take place in Phase II. Once complete, VIVA will provide an efficient, extensible, scalable, and accurate physics-based simulation capability that will enable more definitive and cost-effective decision-making for repair limits and disposition of non-conforming composite components.