AlphaSTAR is a leading global provider of physics based simulation technologies and services for additive manufacturing, structural modeling and analysis of advanced materials. Unlike academic research entities, engineering services companies, or FEA software companies, AlphaSTAR’s products have the ability to provide the end user a complete solution, beginning with material modeling and ending with structural analysis.

AlphaSTAR’s enhanced simulation capability allows in determination of failure, failure modes, strength, life, and safety of structures, thereby enabling engineers to assess where, when, why, and how to remedy failure.

As the use of composite and advanced materials explodes throughout discrete manufacturing, AlphaSTAR’s experience, methodology, and software provides a powerful advantage throughout the development and testing cycles.

Applications of AlphaSTAR

The computational modeling of crush, crash and impact events is a large field of research, which is critical to engineering analysis. Generally, impact corresponds to high speed and high energy events, which may require high strain rate material characterization. In order to conduct a validated test, all cases require true multi-scale analysis in order to accurately predict structural behaviour subject to combined loads and multiple active failure mechanism. GENOA’s PFDA module can do that. Using GENOA PFDA with a commercial explicit FEA solver, engineers are able to

  • Characterize impact resistance of composite structures
  • Predict the impact and post impact behavior of advanced composite laminates
  • Support Service Loading

Additive Manufacturing (AM) represents a transformational process that is evolving at an exponential rate. While AM promises greater efficiency, those gains are lost through rejected parts and wasted material. GENOA 3DP Simulation can address these problems by allowing engineers to:

  • Utilize a detailed material model that corresponds to actual test data
  • Address thermoplastics, thermosets, and powder metal
  • Incorporate the effects of defects, manufacturing anomalies, and environmental conditions
  • Optimize the build to reduce defects
  • Eliminate fabrication trial and error
  • Reduce scrap rate – saving time and money

Fatigue failure—cracking of under repeated stressing—has been a concern of engineering for decades. As sources of vibration and of dynamic loading of materials have increased, fatigue failures have become more common and increasingly important in engineering design. Through many industrial projects MCQ and GENOA have been utilized to predict fatigue behavior in composites, metals, bonded and hybrid structures and which resulted on cost savings and optimal design.

Using GENOA with a commercial FEA solver, engineers will be able to

  • Supports full breadth of 2D/3D composite architectures
  • Determines composite damage
  • Supports Detailed Micromechanical Degradation
  • Supports Service Loading

Planning for certification of an aircraft part or assembly can be a long and challenging engagement which requires a team of experts. AlphaSTAR provides expert assistance in the certification plan development of FAA. AlphaSTARS’s key advantages are :

  • Subject Matter Experts familiar with FAA Part 23 or Part 25 airframe
  • Designated Engineering Representatives for various FAA part Specifications
  • Expertise in Advanced Material Structures & Systems
  • Expertise in Aerospace Engineering
  • Wide network of experts & associates with Vast aerospace manufacturing experience
  • FAA accepted Building Block Analysis approach as means for Virtual Testing in support of Certification process
  • Test-Capable Organization

Structural Health Monitoring (SHM) is an established science which seeks to monitor and detect events due to service and environmental loads. In response to growing need, AlphaSTAR Corporation is developing tools that are aimed for integration into our Active-Passive SHM using GENOA multi-scale progressive failure analysis tool set.  Under a consulting engagement with AlphaSTAR, engineers will be able to:>

  • Utilize sensor data-based diagnostics and multi-scale progressive finite element-based prognostic to detect various loading events and damages
  • Integrate multiple sensors, including PZT, strain gauge, vibrometers, accelerometer and thermo couple to detect impact, buckling and overload events
  • Detect events by hardware
  • Interpret and post-processes data to assess damage and life prediction
  • Exploit diagnostic hardware for event detection, Prognostic Software tool to virtually analyze the state of the structural component, GUI platform to import FE models etc

Generation of A- and B-basis allowable strength values are essential for reducing risk in aircraft structural components made from fiber reinforced polymer composite materials. AlphaSTAR’s technologies are able to determine allowables for laminate level un-notched coupons, while adhering to ASTM standards. Using ASC’s A-B base allowables tools (GENOA, MCQ), engineers are able to

  • Reduce laminate level testing for the first level of FAA’s building block
  • Test reduction of up to 50% as compared to current Industry practices
  • Determine A-basis from B-basis
  • Identify root cause for scatter in material strength
  • Provide guidelines for improving material behavior
  • Applicable to determination of B-basis at any level of FAA’s building block

Lightweighting is a concept about building cars, trucks and aircraft with the least weight possible in order to achieve better fuel efficiency and other preferred characteristics. GENOA PPFA can help engineers evaluate the reliability of a structure in presence of uncertainties in constituent properties of the composite, properties of metal, fabrication variables, geometry, and/or service conditions. Using GENOA PPFA and GENOA PA with a commercial FEA solver, engineers are able to:

  • Calculation of Cumulative Distribution Functions (CDF) and Probability Density Functions (PDF)
  • Calculation of sensitivities of design parameters to the response.
  • Select robust high-fidelity methods (e.g. Advanced Mean Value and Monet Carlo).
  • Study user defined response to improves design durability and reliability.
  • Treats non-statistical uncertainty as a random variable.
  • Predicts failure in increased risk structures (e.g., pressure vessels, leading edge, chassis).

Material scientists recognize the fundamental importance of accurately capturing and quantifying material behavior in order to produce reliable results for structural analysis. AlphaSTAR has made material characterization the basis of its structural analysis capability. Using MCQ, engineers are able to:

  • Determines lamina/laminate limit loads, stresses, and strain
  • Supports multiple failure criteria (including user defined)
  • Supports anisotropic matrix
  • Reduction in testing with cost savings
  • Validated material library
  • Strength allowable for reliability
  • Identification of damage initiation/propagation to failure
  • Identification damage/failure modes

By nature of their construction, advanced materials may be tailored to address specific service requirements. GENOA MS-PFA is a reliable methodology that employs a full-hierarchical modelling. GENOA provides engineers with the predictive computational technology to assess mechanical performance of advanced composite structures. ng GENOA MS-PFA with a commercial FEA solver, engineers are able to:

  • Test Validated Solutions
  • Augment finite element analysis (FEA) with multi-scale composite mechanics.
  • Track damage initiation and fracture propagation
  • Predict and simulate all 5 stages of the damage process.
  • Switch solvers/boundary condition/analysis type before or after
  • Account for defects (void shapes and sizes), fiber waviness, and residual stresses
  • Obtain static solutions with NASTRAN, ABAQUS, ANSYS, OPTISTRUCT, LS-DYNA

Flagship Products

Our flagship products provide innovative physics-based simulation software technologies for material modeling, structural analysis, and additive manufacturing of advanced composites utilized by industries worldwide.

GENOA MS-PFA

GENOA MS-PFA 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.

GENOA 3DP Simulation

GENOA 3DP Simulation is an additive manufacturing design tool and software suite that simulates the 3D printing process to accurately predict the deflection, residual stress, damage initiation, and crack growth formation associated with as-built AM parts.

MCQ

MCQ material modeling software provides engineers with advanced analytic tools to characterize and qualify material properties as input for finite element analysis. MCQ discerns between as-designed, as-built, and as-is material states to predict other design related outcomes