Industry Day - Composite Performance Overview.pdf

DISTRIBUTION STATEMENT A. Approved for public release; distribution unlimited. (AFRL-2024-0769)

COMPOSITE PERFORMANCE RESEARCH

TEAM

C R A I G P R Z Y B Y L A

M A T E R I A L S A N D M A N U F A C T U R I N G D I R E C T O R A T E 6 F E B R U A R Y 2 0 2 4

Materials and Manufacturing Directorate

Metals - Ceramics - Polymers - Semiconductors - Composites - Bio

Dedicated to the Digitization of the Materials Life Cycle

The Full Spectrum of Materials and Manufacturing Competencies

The Magic of Materials & Manufacturing Rare Earth Magnets

Lighter Weight, Higher Performing Systems

(Airframes & Satellites)

Survivable Weapon Systems In Contested

Environments

Cost-imposing materials & manufacturing enables the delivery of transformational and disruptive technology

High-End RF Systems

Composites Specialty Materials

DISTRIBUTION A. Approved for public release: distribution unlimited AFRL-2023-1897

Materials and Manufacturing Directorate Vision

Inventing

That Makes

The Stuff

Inventing the Stuff That Makes the Future

The Future

Materials and Manufacturing Directorate Mission

Accelerate the availability of advanced and cost-imposing materials and manufacturing technologies for the Airman and Guardian by driving the state of the possible and uniting the community

Component Technology System Level Integration & Operational TransitionUniting the Community

How We Do It

Expertise Facilities Partnerships

Resource Allocation at the Materials and Manufacturing Directorate

Internal Development

Capabilities (IDCs)

Research Teams (RTs)

External Dev’mnt

Corporate Initiatives

Organization Investment

~22% of core

~13% of core

~65% of core

Investment Pillars 4 Investment Areas:

1. Research Teams (RTs)

2. Internal Development Capabilities (IDCs)

3. External Development (ExDev)

4. Corporate Initiatives (CIs)

• Internal Development Capabilities (IDCs) - Strategic, organic in-house capabilities and facilities

• Corporate Initiatives (CIs) - Long term strategic investments aligned with DoD/DAF/AFRL priorities

• External Development (ExDev) – Programs executed externally with industry, service research laboratories, and AFRL TD’s

• Research Teams (RTs):

• High-risk / high impact, awareness of state of possible (Tech Surprise)

• Assess “science readiness” and limiting issues, accelerate translation through partnerships

• External engagement to connect with global experts

• Priority Balance between 1/3 local, 1/3 Enterprise, 1/3 Competency

Research Teams: World-Class Scientists & Engineers

Metals Metals Probabilistic Performance Prediction

Metals Materials & Processing

Inspection Characterization Sensing and Analytics

Soft Matter Biological Materials & Processing Polymer and Responsive Materials

& Processing

Semiconductors Integrated Opto-Electronic Materials & Processing

Agile RF Electronic Materials & Processing

Manufacturing Digital Manufacturing

Composites PMC Materials & Processing

Ceramics Materials & Processing Composites Performance

Optics Structured Optical Materials & Processing

Non-Linear EM Materials & Processing

What is the Composite Performance Research Team?

High-priority Application Areas https://www.thedrive.com/the-war-zone/10475/usaf-research-lab-has-released-this-image-of-its-low-cost-stealthy-drone

CMC: Durability and performance prediction for hypersonic Structures and propulsion

EMC: Multifunctional performance of EM CompositesPMC: Performance and design optimization of autonomous collaborative platforms https://www.aerodefensetech.com/component/content/article/adt/featu res/articles/38910 https://afresearchlab.com/technology/hypersonics/

Vision:

Mission: We pioneer physics-based and machine learning approaches for the performance prognosis of composites in application relevant environments, driving optimized materials design across length scales, timely manufacturing assessment, and real time in-service diagnostics, to ultimately foster the development of material aware systems for the United States Air and Space Forces.

What are Material Cognizant Systems?

Systems designed, manufactured, operated, and sustained based on a predicted performance of the current material state

What are Material Cognizant Systems?

Tony Stark (Robert Downey Jr.) uses a cool-looking but somewhat cluttered Head-Up Display (HUD) in his Iron Man suit. (Marvel Comics/Paramount Pictures) (https://breakingdefense.com/2018/03/hud-

3-0-army-to-test-augmented-reality-for-infantry-in-18-months/) The view of the wash rack on the Edwards flight line through the Replacement Head-Up Display on an a C-17 Globemaster III. (https://www.afmc.af.mil/News/Photos/igphoto/2001887241/)

Today we … Provide flight information but lack the ability to assess system ability to meet mission requirements considering current materials state.

In the future we … Will provide assessment of system ability to meet mission requirements as a function of current material state (e.g., battle damage) https://breakingdefense.com/2018/03/hud-3-0-army-to-test-augmented-reality-for-infantry-in-18-months/ https://breakingdefense.com/2018/03/hud-3-0-army-to-test-augmented-reality-for-infantry-in-18-months/ https://www.afmc.af.mil/News/Photos/igphoto/2001887241/

Increased Performance Complex Geometries

Weight Temperature

Processing to performance modeling

Affordability Speed/Agility

Cost Maintenance

Performance and certification of AM

Composites

Composites for Space Radiation Effects

Cost Temperature

Composite durability in radiation, AO, and reentry conditions

Demand Signals and how Composite Performance Meets Each One

Cost Capability

EM Shielding

High Performance / High Temperature

Conductive Composites

Increased Survivability

FY24 Composite Performance Priorities

• Performance of high temperature composites in extreme environments

• Multiscale experimental characterization and response measurement in extreme environments (e.g., testing up to 1200C in SEM, HT inert testing up to 2500C, accurate temperature and strain measurements)

• High fidelity response prediction (e.g., CDM, interacting discrete crack modeling, large scale simulation)

• Multi-functional Composite Performance

• Optimization of hybrid composites for functional performance

• Optimization of microstructure interfaces for structural performance

• Machine Learning for Real Time Assessment

• Surrogate models for performance prognosis with damage progression (requires sampling of extreme value statistics)

• Space Radiation Effects for Composites

• Development of a new laboratory for testing composites in combined Atomic Oxygen and UV radiation

• Laboratory Modernization

• Development of seamless data streams between experiments and simulations (e.g., CARBYN)

• Adoption of cloud based project level data structures (e.g., Gitlab, Hyperthought)

Let me introduce you to our Government Team!

Vikas Varshney Multiscale Modeling, AI/ML

Keith Ballard Computational Mechanics

George Jefferson Comp./Exp. Mechanics in Extreme Env.

Craig Przybyla Comp. Mech. in

Extreme Env., AI/ML

David Mollenhauer Exp./Comp. Mech.

Katie Detwiler Extreme Env. Exp. Mech.

Dhriti Nepal Multifunctional Composite Experimental Mechanics, Chemical Properties

Ashley Hilmas Extreme Env. Exp. Mech.

Mark Flores Exp. Mech., AM

Erik Ripberger Business Manager

Multiscale physics-based damage modeling thrust Progressive damage modeling

0/-60 interface

60/0 interface

Microstructure/architecture representation

High Performance Computing

(>1B DOF)

Performance of additive joints

Unit cell weave model

Cycle-by-cycle modeling of infusion, cure, pyrolyzation, stress, damage

Cycle-by-cycle CT imaging for model calibration and verification

Process to performance modeling

Enviro-mechanical composite structure-property characterization in Extreme Environments thrust

In-situ Characterization of Enviro-mechanical Damage Evolution in Hypersonic Materials

Automated Microstructure Characterization of Continuous FRC from X-ray CT Data

Multiscale performance characterization of PMCs

Performance of bonded C/C µm

Coupled structural-functional performance of multifunctional composites thrust Multi-functional performance characterization Photo-Thermal Healing of Vitrimer Nanocomposite

Healed

Performance of 2D material filled composites

Graphene MXenes

ML/AI assisted performance prognosis thrust

Input Output Machine Learning

Model

Technology highlights include progressive damage modeling and architecture simulation, MXene composites for EM protection and CMC processing to performance modeling

Damage Modeling and Architecture Simulation

MXene Composites for EM Protection

CMC Processing to Performance Modeling

• Providing damage tolerant composite design and certification approach

• Architecture dependent process modeling

• Large scale simulation (2B DOF problems)

Model Experiment

USAF Program: “VTMS has enabled us to save over $3M/aircraft”!

Architecture Simulation

• Next-gen lightweight EMI shielding

• MXene based structural composites

Algorithms are currently being transitioned through SBIR programs!

• Processing simulations of ceramic matrix composites (CMCs) for hypersonics applications

• As processed performance prognosis

MXenes provide a new capability!

Digital Infrastructure

Analysis

QR based tracking

• IT systems now available on demand

• Utilizing cloud computing resources (G-Suite)

• Creating a digital laboratory

• HYPERTHOUGHT - Cloud-based project centered data repository

• CARBYN – Laboratory enclaves accessible by RD&T network

• Status: X-ray CT Connected Laboratory

• NORMS - No Omission Research Management System

• Logbook Viewer - Local logbook of system activity

• BASS - Barcode And Specimen Station, Documents the physical objects used to take measurements

• EASEL - Experimental And Simulation

Electronic Logbook, Ensures metadata is created when measurements are taken

What do our partnerships look like?

International (Project Agreements)

Industry (CRADAs)

University Co-funded Projects

Government (Joint Projects)

Research Team Facilities

Recent equipment upgrades features...

• Laser heating

• Vacuum/inert environment In design Estimated completion Aug 2023 features...

• 1200°C Temperature Capability

• Edge on sample viewing

• Vacuum environment Delivered, Aug 2022

~$3M investment!

features...

• Low profile

• Two sided imaging

• Dual actuators Estimated completion May. 2024

Recent equipment upgrades features...

• New electro-mechanical load frames

• New high temperature test fixtures and measurement Completed March 2023

$3M investment!

features...

• 2500°C Temperature Capability

• 8 in diameter by 10 in high hot zone

• Vacuum/inert environment Delivery: June 2023

Desired features...

• High temporal resolution, <3s

• Dynamic micro-CT for engineering materials, lab synchrotron-like capabilities

• Spectral CT capability : discloses chemical samples’ composition

Estimated delivery 2024

Facilities & Capabilities Microstructure Characterization Facility (RX asset)

• SEM, TEM, FIB, sample prep., etc.

X-ray CT Characterization Facility

• In-situ testing

• Synchrotron facility access (ALS, CHESS, Argonne) Chemistry Characterization Facility

• AFM – IR with in-situ testing capability Multi-scale extreme environment characterization facility

• Optical microscope, SEM (1200C), in situ testing

• High Temperature Vacuum Furnace (2500C)

• Servo hydraulic fatigue testing (1400C)

• Electromechanical testing for strain sensitive tests

• RT/High-Temperature AE, DIC

• Multiaxial loading (bi-axial, torsion)

• High energy laser heating (RHINO)

• Burner rig testing

Prime Capability Areas:

Materials Characterization Facility (MCF)

7 FTEs spanning: SEM, TEM, FIB, 3DAP, EDS, EBSD, EPMA, soft/cryo, metallography, X-ray, in-situ mechanics, EELS/EFTEM, …

Scanning Electron Microscopy SE, BSE, EDS, EBSD, in-situ, E-beam lithography, EPMA

Focused Ion Beam & Laser Milling

In-situ lift-out, micro/nano manipulation

Transmission Electron Microscopy

Quad-EDS, EELS/EFTEM, Icor, Cryo, holography, liquid cell

X-ray Diffraction & CT n-CT and powder diffraction

Microstructure & Crystallography Chemistry & Defects

Functional Performance

X-ray Atomic Resolution & Bonding

Microstructure Simulation & Data Analytics

Xradia - 620 Xradia - 520 Xradia - 800

Resolution 0.1 - 115 µm 0.30 – 10 µm 0.016 -0.060 µm

Sample Size 0.03 – 14 cm 0.2 – 5 cm < 0.05 cm

Materials CMCs, PMCs, ceramics, Metals, Polymers Electronics, CMCs, PMCs, Metals, Polymers, Organic Materials

Super thin metals, OMCs, Organic Materials

Voltage 30-160 kV accelerating voltage 30-160 kV accelerating voltage 5.4 keV X-ray energy

Source Rotating tungsten anode-transmission source Rotating tungsten anode-transmission source Chromium/copper target reflection source

Apparatus Movable source, detector & stage, large field for bigger samples

Movable source, detector & stage Fixed source/detector distance with movable stage

Magnification Cone beam and optical magnification (0.4x, 4X, 20X, 40X)

Cone beam and optical magnification (4X, 20X, 40X)

LFOV & HRES

Average Scan Time < 3 - 10 hrs 12-30 hrs 24-86 hrs

X-ray Computed Tomography Laboratory

World's highest performance / resolution large-sample AFM

Topographic & mechanical properties data in parallel

Monolayer MXenes - Visualization

Atomic Force Microscopy (AFM) Dimension ICON

Damage Zone

25 mm m m

In-situ Mechanical Testing

Crack tip

SEMTester100

0 50 100 150 200

Strain [%]

St re ss [M

Pa

Strain-induced crystallization via in situ AFM

In situ Mechanical Testing with AFM

Photo-thermal AFM-IR (Sub-10nm)

Tapping AFM-IR Chemical mapping at the highest spatial resolution, while providing high-quality IR spectroscopy

AFM - IR

Mechanical Testing Facility - Custom Horizontal Frame in Enclosure (SH22):

• MTS 661.19 Load Cell (12500N = 10V):

‒ 25kN Capacity/12.5kN Cal Range (12500N = 10V)

• MTS 647.02 Wedge Grips:

‒ 25kN, Water-heated (80°C) ‒ Smooth wedges; no tabs on specimens (GENi2) ‒ Surfalloy wedges; no tabs; diamond grind surface prep (A600)

• AMTECO 3-Zone Furnace (1400°C):

‒ SiC Ignitors, Barber-Coleman Temp Controllers, S-Type TCs

• Epsilon HT Extensometer w/SiC rods (0.123mm = 10V):

‒ SN E92076; GL = 25.225mm; 0.5% max strain; water-cooled (15°C)

• MTS Controller/Software:

‒ FlexTest40 / MTS 793 / MPT

• Enclosure Heater:

‒ Hatco Glo-Ray Foodwarmer (S/N 8786172135)

• 8-Pole Low-Pass Butterworth Filters:

Mechanical Testing Facility – Information Rich Testing (DIC)

• MTS & Correlated Solutions Systems

• Point Grey CSI-5MP Cameras

• Variety of Lenses….

‒ 3D set up – Schnieder High Res 35mm ‒ 2D set up – Tamaron Macro 180mm

• Blue LED and other white lights

• External Signal Input & Triggering

‒ NI USB 6542

• Capture & Analysis Software:

‒ ViC Snap 8 ‒ ViC 3D 7 ‒ ViC 2D 2009 ‒ UDRI Code – MatLab (Pete Phillips)

Modal Acoustic Emission Analysis

• Hexagon Digital Wave

• FM-1 (8 channel)

• Single mode: sync

• 0.5V amplitude range

• Physical Acoustics

• Micro II Express (8 channel)

• Multi-mode: sync, independent, streaming

• 10V amplitude range

• AE Sensors ‒ Broadband: 20 – 2000 kHz

Dimensions: 9.3mm(0.37in) OD X 12.7mm(0.5in) H Temperature Range: -50 deg C to 150 deg C

‒ Pico: 200 – 750 kHz Dimensions: 5mm(0.2in) OD X 4mm(0.15in) H Temperature Range: -65 deg C to 177 deg C

Broadband AE Sensors

2 sets of 2 sensors at each end of the specimen gage length for tracking change in time of flight with load/displacement

Pico (Mini) AE Sensors

Mechanical Testing Facility – Information Rich Testing (AE)

AFIT / AFRL Burner Rig Test System

• HVOF atmospheric burner with servo-hydraulic load frame

– Mechanical damage + oxidative degradation unique to combustion environment

– Combustion Products

– Thermal Gradients

– Mechanical Loading Conditions

25kN MTS inverted servo-hydraulic frame

High-Velocity Oxygen/Propane flame for specimen heating

Test Configuration Current Capability

Surface Temperature 1316oC / 2400°F (Front)

Gas Temperature Exceeding 1800oC

Gas Velocity ~ Mach 0.5

Equivalence Ratio ~ 0.9

Gas Composition H2O, O2 ,CO2, CO, NOx, Thermal Cycling Range: 315-1316°C (600-2400°F) [Front]

Mechanical Loading 25 kN capacity, MTS FlexTest 40 controller

Themo-Mechanical Cycling Combination of thermal and mechanical loading to better simulate turbine engine environment

Test Duration Up to 8 hr sessions

RHINO (Rapidly Heated INvestigation Of) Materials Laboratory

HIGHLIGHTS:

• IPG fiber laser ~1 kW @ 1069.2 nm

• Water-cooled Pi-Shaper (gaussian to flat top converter)

• Sintech 20/G tensile machine (30 kN load cell)

• Real time radiography (30 fps X-Ray video)

• Perkin Elmer UB-VIS-NIR Spectrometer (200-2500nm)

• HD DVR and National Instruments data acquisition equipment

• Beam profiling cameras (UV to LWIR) and direct high power measurement

Employing laser heating to Conduct thermal, chemical, optical, and mechanical evaluations of materials in conjunction with a suite of non-contact in situ monitoring.