Multiscale failure analysis of a 3D woven composite containing manufacturing induced voids and disbonds

Multiscale failure simulations of a three-dimensional woven composite repeating unit cell considering six scales, spanning the woven composite mesoscale to the sub-microscale voids, have been performed. The multiscale recursive micromechanics approach, which enables recursive integration of general micromechanics theories over an arbitrary number of length scales, has been employed within the NASA Multiscale Analysis Tool. The multiscale model uses both the generalized method of cells and Mori-Tanaka micromechanics theories and considers failure in the constituent materials using a simple damage model. Baseline results, from a model of a composite containing distributed voids, are compared to uniaxial experimental data for an AS4 carbon fiber/ RTM6 epoxy matrix orthogonal three-dimensional woven composite with good agreement in terms of global stiffness and global failure stress. The multiscale model is then used to examine the nonlinear response of the material to other loading conditions. Case studies, motivated by X-ray computed tomography data, are presented on the effects of manufacturing induced voids and cracks.