The material uncertainty resulting from variability in VARTM composite material processing has driven the present design based on the “knock-down factor (factor of safety)” approach. The coarseness of marine-grade composites has prevented development of a useable process model by which the effects of the processing parameters may be predicted. There is an immediate need to assess the effect of processing uncertainty on thermal-mechanical properties and their subsequent impact on structural response, damage accumulation, and ultimate failure. In this paper, a multi-scale, probabilistic analyzer is developed by integrating the existing micromechanics-based woven fabric analysis module (TMAT) and a laminated plate solver with a probabilistic analysis framework. The effects of processing induced random constituent and microstructural parameters on the ply properties are determined first and then propagated into the laminated composite plate model. The sensitivities of these random parameters on the variability of ply and laminate stiffness matrices are also determined to identify the dominant contributor to enhance the ply/plate stiffness.

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