Towards the Development of Multiscale Digital Twins for Fiber-Reinforced Composite Materials Using Machine Learning

Brandon L. Hearley, Evan J. Pineda, Brett A. Bednarcyk, Joseph R. Baker, Laura G. Wilson

Material considerations are often neglected when developing digital twins, particularly at the relevant length scales that drive material and structural performance. For reinforced composite materials, the microscale has the largest impact on nonlinear material behavior and progressive damage, and thus accurately representing the disordered microstructure of a composite due to processing and manufacturing is critical to developing the material digital twin in the multiscale hierarchy. Automating microstructure characterization is typically done by either training convolutional neural network models using a pretrained encoder or using prompt-based segmentation tools. In this work, a toolset for developing segmentation models is presented, combining these two methods to enable rapid annotation, training, and deployment of microscopy segmentation models for automated material digital twin development without user knowledge of machine learning. Additionally, a Bayesian optimization framework is developed for generating statistically equivalent representative volume elements (SRVE) to a segmented microstructure using a random microstructure generator that implements soft body dynamics. Progressive failure analysis of random, statistically equivalent, and ordered microstructures is compared to the segmented microstructure subject to transverse loading to demonstrate the importance of accurately representing the driving material length scale of a composite digital twin. Ordered microstructures over-predicted crack initiation and ultimate strength and strain. Random and optimized RVE microstructures better agreed with the segmented simulation results, with no significant difference observed between the two methodologies. The improvement in predicted macroscale behavior for models that capture disordered microstructures due to manufacturing processes demonstrates the importance of capturing microstructure features in composites modeling and indicates that SRVEs that capture microstructural features of the physical material can be used in material digital twin development. Further, the toolsets provided in this work allow for rapid development of composite material digital twins without user expertise in machine learning. This has enabled the development of an integrated workflow to automatically characterize and idealize composite microstructures and generate representative geometric models for efficient micromechanics analysis.