ComMUnion at American Society for Composites (ASC) 33rd Annual Technical Conference
- Seattle WA, United States,
ESI GROUP at ASC presenting results of ComMUnion project in the conference Multi-scale analysis of joints in hybrid metal/composite structures in ESI VPS
Local strengthening of steel parts through hot forming leads to poor metallic joints with a high crack risk due to local metallurgy changes during welding. In a first step, a welding process simulation is performed to predict the local heat degradation of the material and corresponding mechanical behavior in the joint. Failure prediction on the detailed model allows two options: macroscale models adapted to efficient car crash models with 1D simplified beam connector, or a multiscale approach with a detailed 3D model for more accurate zooming on specific areas. Reinforcement of steel components is investigated in the specific case of laying thermoplastic composite tapes (using the ATL –Automatic Tape Laying - process). An important parameter for the structural strength is the texture of the metal surface. It is linked to both the texturing process and the laying of the thermo-plastic tapes. A microscale model of the textured metal and composite interface is built automatically based on real-life micrographs. It is then used to assess microscopic damage evolution near the interface and to numerically characterize the joint and build up macro scale cohesive zone elements. A mixed material structural component is then evaluated with metallic and composite to metal virtually-characterized joints.