Multiscale numerical and experimental analysis of cooling-induced thermal shrinkage behaviors and residual stresses in 2.5D woven fiber/aluminum matrix composites

The cooling-induced thermal shrinkage behavior and residual stress in fabrication of 2.5D woven fiber reinforced Al composites were investigated by numerical and experimental approach. A microscale finite element (FE) model was established to determine the transversely isotropic thermal shrinkage of the Al-impregnated yarns. The validated properties were subsequently input into a mesoscale FE model for the composites, in which the temperature-dependent properties of the constituent materials were incorporated. Parallel experiments were carried out to verify the thermal shrinkage behaviors and the residual stresses that were predicted by the FE simulations. The residual stress distribution of the matrix pocket, warp and weft yarns were studied, and their contributions to the local damage of matrix pocket and interface were analyzed. Based on the verified model, the effect of fabric structure on the residual stresses and macroscopic shrinkage properties were parametrically evaluated. The results make a contribution to evaluating the cooling-induced residual stress, local damage, and shrinkage behavior of metal matrix composites reinforced with complex fabric.