Durability analysis of composite structures using the accelerated testing methodology

The applications of composite materials are increasing significantly due to their excellent properties and design flexibility, and composite materials have completely replaced conventional metals in several applications. However, much larger opportunities will be likely to occur when physical bases for durability characterization become established. Polymeric composite materials are in general viscoelastic, and their stiffness and strength depend on temperature and loading rate. These effects play an important role in the long-term durability of the composite materials, and therefore it is important to develop a durability analysis method for composite structures that considers these effects.; The present approach is based on three components, a new accelerated material characterization methodology, statistical analysis of this methodology, and conventional design tools tailored for the temperature and loading rate dependence. The material characterization methodology uses series of short-term tests at elevated temperatures to predict life for wide ranges of temperature and loading conditions. This methodology is based on the empirical relation between the effects of temperature and loading rate on the stiffness and strength of polymeric composite materials. The statistical analysis allows us to create the confidence interval of the prediction, which is essential in generating the design allowables. Common design tools such as failure criteria and cumulative damage laws can be tailored to consider the temperature and loading rate dependence. These components are integrated into the proposed durability analysis and design method for composite structures.; The durability design of a composite rotor for the flywheel energy storage system is shown as an example. This example demonstrates that the proposed design method is not significantly different from conventional designs in terms of complexity and required effort.