Advanced Manufacturing and Modeling of Composites at the U.S. Air Force Research Laboratory

The Materials and Manufacturing Directorate at the U.S. Air Force Research Laboratory has a long history of scientific and
engineering investments in composite materials. It has focused both on manufacturing methods and behavior modeling, with a more recent emphasis on the integration of process modeling with performance modeling, the so called Integrated
Computational Materials Engineering (ICME) approach. Traditional manufacturing methods such as hand layup, advanced tape placement, and simple textile weaving are being augmented with new methods and a resurgence of interest in thermoplastic resin systems. Dr . Mollenhauer will share current progress on externally funded efforts in manufacturing demonstrations using new techniques, infused with select AFRL in-house technology. Building on the ICME theme, the talk will cover AFRL’s efforts in “dry-fiber mechanics”, a form of process-modeling specific for textile architecture composites. Following this, Dr . Mollenhauer will discuss his team’s development of a high-fidelity damage simulation method known as discrete damage modeling (DDM). This method models each observed damage mode as their own separate discontinuity, with growth generally governed by fracture mechanics. Bringing dry-fiber mechanics process simulation together with DDM, an ICME-centric textile compression experimental/modeling campaign will be discussed.