AlphaSTAR Corporation Long Beach, CA, USA alphastarcorp.com

Authorized AlphaSTAR Distributor

AlphaSTAR Corporation provides innovative physics-based simulation software technologies for additive manufacturing, material modeling and analysis of advanced composites structures in the aerospace, automotive, defense and energy industries worldwide. Offering unique capabilities in fatigue, durability & damage tolerance, our tools will support engineers throughout the design cycle – from experimental testing to end-product fabrication. AlphaSTAR team consists of material scientists, educators, and industy professionals working together to leverage thirty plus years of subject matter expertise in testing, simulation and computational analysis of advanced materials & structures.

Software Products:

Figure below shows a full cycle of capabilities available via AlphaSTAR software tools.

AWARDS & PUBLICATIONS 2x R&D 100 Award, NASA Columbia Accident Investigation Board Award; US Senate/Tibbetts Small Business Administration Award; NASA Turning Goals Into Reality; NASA Software of the Year Award; NASA Best of the 90’s; 400+ Technical Publications; 100+ peer reviewed Journal articles and 5 Books

Authorized AlphaSTAR Distributor

GENOA is a durability & damage tolerance, progressive failure, and reliability software that provides engineers with

predictive computational technology to characterize and qualify advanced composite materials and structures. Through

GENOA’s true De-Homogenized Multi-Scale Progressive Failure Analysis, engineers are able to assess failure at the macro,

micro and nano levels for advanced materials and composite structures subject to static, fatigue, impact and environmental

loadings. Using a closed-form, de-homogenized, analytical methodology, the software is integrated with building block

strategies which result in the accurate assessment of failure and test reduction. GENOA’s ability to assess damage, fracture

initiation and evolution, integrate the damage & fracture mechanics, and determine percent damage contribution make it

a unique tool for advanced structural design.

Key Features:

✓ Multi-scale, Micromechanics Toolset

✓ De-Homogenized: examines fiber, matrix, interface,

interphase

✓ Augments commercial finite element solvers

(Abaqus, Ansys, LS-Dyna, Nastran, etc.)

✓ Damage/Fracture Evolution

✓ Assess Durability and Damage Tolerance

✓ Identifies Where, When, Why and How Failure Occurs

✓ Includes failure mechanism percentage contribution

Key Benefits:

✓ Predict structural performance considering defects

(void, fiber waviness, curing and residual stress)

✓ Modeling and simulation of complex parts and

materials

✓ Address design envelope parameters

✓ Compatible with HPC for parallel processing of large

complex models

✓ Guides test by analysis to reduce testing up to 65%

✓ Optimizes design of lightweight structures and vehicles

✓ Delivers greater accuracy with minimal computational

overhead

Authorized AlphaSTAR Distributor

Modules

• GUI Base GUI for project management, setup and post-processing results

• Progressive Failure (Static) Predicts the maximum loads that composite and metallic elements and structures can sustain using a step-by-step virtual loading procedure that takes into consideration material degradation, nonlinearity and changes in structural geometry.

• Random Fatigue (Spectrum Loading)

Determines the fatigue life of composite or metal structures subject to a sequence of external cyclic excitations with variable amplitude and period

• Power Spectrum Density Evaluates various mode shapes for the fatigue life of composite and metal structures subject to dynamic loads of constant amplitude and vibration frequencies

• Progressive Failure Dynamic Analysis

Performs progressive failure analysis of composite structures using an explicit transient dynamic algorithm, integrating GENOA with the LS-DYNA software.

• Aging Effective evaluation of the aging with time of metallic and composite structures subjected to either static loads of constant amplitude, or sequence of external cyclic excitations with variable amplitude and period.

• Quasi-Static (Low Cycle) Effective evaluation of the fatigue life of composite and metal structures subject to static loads of

constant amplitude

• Harmonic Fatigue (High Cycle)

Evaluates the fatigue life of composite and metal structures subject to dynamic loads of constant amplitude

• Fatigue with Fracture Mechanics

Effectively evaluates the fatigue life of a metal structure by combining the Progressive Failure Analysis-Virtual Crack Closure Technique (PFA-VCCT) and Fatigue Crack Growth (FCG) modules together

• Virtual Crack Closure Technique

Fracture mechanics based approach for the progressive crack growth analysis integrated into GENOA-PFA.

• Discrete Cohesive Zone Model

Cohesive damage model for delamination and crack growth analysis integrated into GENOA-PFA

• A- & B-Basis Allowables Simulation

Effectively reduces the number of coupon testing by simulating the scatter in composite material properties and fabrication parameters

• Parametric Carpet Plot Generates carpet plots of laminate properties as a function of percent 0°, +/-45° and 90° plies

• Filament Winding Design and analysis of composite over-wrapped pressure vessels (COPVs). GENOA-FW combines advanced composite mechanics with a special module for filament winding analysis

• Probabilistic (PA) Permits the simulations of progressive failure in composite structures taking into consideration uncertainties in material properties, loading conditions and service and manufacturing environments

• Material Non-Linearity Predicts the in-situ matrix stress strain curve from in-plane shear ASTM standard test data. The analysis can be used to reverse engineer any fiber or ply nonlinearity as well.

• 3-D Printing Imports G-Code printer data and creates FEM simulations based on Thermal and Structural analysis with user material properties

• Orientation Tensor Mapping Map donor mesh to receiver mesh and perform transform layup based on orientation tensors and material properties

• Abaqus (V)UMAT Perform Multi-Scale Progressive Failure Analysis & Progressive Failure Dynamic Analysis (MS-PFA & MS-PFDA) as an ABAQUS Subroutine

• Ansys UMAT Perform Multi-Scale Progressive Failure Analysis (MS-PFA) as an ANSYS Subroutine

• LS-Dyna UMAT Perform Multi-Scale Progressive Failure Dynamic Analysis (MS-PFDA) as a LSDYNA Subroutine

AlphaSTAR Corporation

Long Beach, CA, USA

www.alphastarcorp.com / info@alphastarcorp.com

GENOA 3DP Simulation is an additive manufacturing design tool and software suite that simulates the 3D printing

process to accurately predict the net shape, residual stress, deformation, damage initiation, and propagation associated

with as-built 3D printed parts. Advanced Multi-Scale Progressive Failure (global/local) modeling and analysis methods are

used to replicate the entire 3D printing process from the level of Material Characterization to Advanced FE Analysis by

either predicting or utilizing manufacturing anomalies, and other irregularities and inefficiencies from micro to macro scales.

More significantly, GENOA 3DP Simulation provides the end user with an ability to generate a structural mesh, run analysis

and optimize the build in order to reduce weight, reduce scrap rate, improve performance and meet specification.

Key Features

✓ Supports Metal Powder and Polymer Material Systems – validated material databases for Metals/Polymers/Ceramics

✓ Predicts Mechanical Properties with Voids and Anomalies at Room and Elevated Temperatures

✓ Assesses both Material and Process Parameter Sensitivities to be Optimized to Improve Manufacturing Process

✓ In-service Qualification of Printed Part, Effect of Voids and Defects on In-service Life, Strength and Durability

✓ Predicts Manufacturing Anomalies (e.g. Residual Stress, Warpage, Heat Affected Zone, Delamination, etc.)

✓ Visualizes/Assesses Printer Path Quality and Highlights Problematic Bald Spots, 2D/3D Voids Visualization

✓ Creep Diffusion Model to Predict Local Anomalies, Voids and Local Surface Roughness

✓ Predict Transient Temperature & Material Phase / States - Zeroth Order Model for Thermal Analysis (ZOM)

✓ Predict Damage/Failure Type, Location and Percentage of Contribution of Each Failure Type to Fracture

Key Benefits

✓ Reduces Scrap Rate of Materials in Additive Manufacturing, Trial and Error in Manufacturing Process

✓ Characterizes AM Materials in Coordination with an ICME Framework

✓ Integrates 3D Printing Process Simulation with Assessment of Properties, Design Evaluation and Structural Analysis

✓ Provides Improvements for Process Parameters and Robust Design Optimization in Order to Minimize Defects

✓ Addresses Manufacturing Constraints to Minimize Processing Defects to Improve Performance

✓ Validates Developed/Enhanced Models for AS-IS Performance of 3DP Parts

FE Model Generation

In-Service Qualification

Build Optimization

Additive

Manufacturing

Simulation Solution

Service Load

0

200

400

600

800

1,000

1,200

0 1 2 3 4 5

True

Str

ess

(MPa

)

True Strain EPS (%)

SS Curve Ti 6Al 4V

Wrought

Wrought with Air Particles

As-Built LENS

Thermal Analysis Thermal-Structural Analysis

Process Simulation/Prediction

Multi-Scale Material Characterization

AlphaSTAR Corporation Long Beach, CA, USA alphastarcorp.com

Authorized AlphaSTAR Distributor

MCQ (Material Characterization & Qualification) - is a material modeling toolset providing engineers with advanced analytic tools to characterize and qualify material properties as input for finite element analysis. Starting with results of standard ASTM tests, fiber volume, density, resin content and void volume, MCQ reverse engineers in-situ constituent properties of fibers and matrix while taking into consideration manufacturing anomalies, effect of defects, complex

architectures, effect of environment and scatter. Next, MCQ reconstitutes the laminate (test coupon) and calibrates effective properties against tests, utilizing standard and user defined failure criteria. In this manner, MCQ discerns between as-designed, as-built, and as-is material states to predict other design related outcomes, such as:

❖ laminate properties (thermal-hygral-mechanical-electrical) ❖ properties related to electrical conductivity, resistivity, and dielectric effect ❖ load limits and damage/failure modes ❖ parametric carpet plots ❖ -A and –B Basis Allowables ❖ material properties for 2D/3D fabric/weave/braided composite lamina/laminates.

❖ ABD and engineering constants used as input for commercial FEA solvers.

The MCQ suite of software consists of MCQ Composites, MCQ Chopped, and MCQ Ceramics. MCQ suite of software addresses continuous fiber, discontinuous fiber, ceramic matrix, metal matrix, and hybrid systems. MCQ supports a

library of validated classes of composite materials in order to make better parts, better components and, ultimately, better solutions. Ultimately, MCQ facilitates material qualification, modeling, and design analysis so that, in a very short period of time, end-users can generate vast amounts of information concerning composite material system.

GENOA UMAT/VUMAT

AlphaSTAR Corporation

Long Beach, CA, USA

alphastarcorp.com Authorized AlphaSTAR Distributor

GENOA UMAT/VUMAT allow engineers to perform Multi-Scale Progressive Failure Analysis (MS-PFA) as

Abaqus, Ansys or Ls-Dyna subroutines. This capability augments Implicit and Explicit Finite Element Analysis

with composite damage micromechanics. The resulting output identifies the "root cause" of damage in the

matrix and fiber using dedicated physics-based failure criteria, which determine when, where and why failure

occurs. Further it provides a mechanism to track all 5 stages of damage evolution under static, impact, crush,

or crash loading conditions and calculates micro-cracks in the matrix, delamination within the plies, and fiber

failure in tension and compression.

Drop TestDisplacement Filed Prediction

Using Finite Element Simulation

Damage Assessment using GENOA MS-PFA

Key Benefits: ✓ Rapid assessment of composite static, impact and post

impact damage tolerance ✓ Reduction in physical tests by over 65%

✓ Verification of results with test for Polymers

(chopped/continuous, thermoset, thermoplastic); Elastomers, Ceramics, and Metals

✓ Multi-scale Progressive Failure Analysis Modeling/Prediction Capabilities

✓ Identification of damage initiation and propagation to final failure & modes of damage/failure

✓ Identification of damage types and magnitude to assess risk

Key Features:

✓ Supports 2D/3D composite architectures

✓ Supports isotropic and orthotropic materials

✓ Determines composite damage

✓ Supports Failure Criteria (In-built/User Defined)

✓ Supports Detailed Micromechanical Degradation

✓ Supports Service Loads (Static, Impact and

Fatigue)

✓ UMAT and VUMAT supports solid and shell

elements in implicit and explicit simulations. Layered solid in implicit only.

✓ Linux/Window, cluster parallel processing

supported