Computer methods are utilized to evaluate the progressive damage sod fracture tolerance characteristics of space structures. Progressive failure, reliability and durability analyses assist in life prediction of the X-37 mini space plane's composite sandwich structure. As part of the future X-37 design, the progressive failure analysis (PFA) is intended to reduce the X-37 development cost by accurate life predictions and margin of safety to ensure performance while controlling weight for this reusable launch vehicle. 30% test saving, and up to 50% cost saving on product development and processes, using virtual testing PFA includes algorithms needed for simulating the progression of damage from various source defects. The mathematical modeling involves an integration of simulations at multiple hierarchical scales ranging from macroscopic (lamina- laminate-and structure) to the microscopic (fiber matrix interface) level. GENOA PFA uses a "Building Block" methodology in the design process, in accordance with congressional certification requirements: FAR125 and AC128. This modeling process includes micro mechanics, elemental, sub-elemental, flight profile verification and mission trajectory. An integrated simulation strategy includes hierarchical evaluations of micro-mechanics, macro-mechanics, element, sub-element, and global model predictions encompassing polymer, ceramic and metallic constituents.
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