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Prediction of process-induced deformation in CFRP multispar flaps using sequentially coupled thermomechanical analysis considering fabric patterns and stacking sequences

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  • Published: 14 March 2026
  • article number , (2026)
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Advanced Composites and Hybrid Materials Aims and scope Submit manuscript
Prediction of process-induced deformation in CFRP multispar flaps using sequentially coupled thermomechanical analysis considering fabric patterns and stacking sequences
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  • Dong-Hyeop Kim1,3,
  • Sang-Woo Kim1,2,3 &
  • Tae Su Kim4 

We are providing an unedited version of this manuscript to give early access to its findings. Before final publication, the manuscript will undergo further editing. Please note there may be errors present which affect the content, and all legal disclaimers apply.

Abstract

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This study presents a sequentially coupled thermomechanical FE-based approach for analyzing process-induced deformation (PID) in CFRP multispar flaps during the curing cycle. The proposed method enables a detailed investigation of curing behaviors by incorporating critical material characteristics, including complex curing properties and fabric patterns. A two-step simulation framework, integrating heat transfer and mechanical analyses, was employed to evaluate the effects of thermal gradients, cure kinetics, and thermochemical deformation on PID. The results revealed significant temperature gradients influencing the degree of cure (DoC) and PID throughout the curing cycle. By the end of the process, the temperature distribution became uniform, and the DoC stabilized at approximately 0.91. PID behaviors transitioned progressively throughout the curing stages, with thermal expansion prevailing during early deformations, while chemical and thermal shrinkage became the primary factors in subsequent stages. These findings indicate that minimizing deformation necessitates not only the optimization of geometric designs but also the precise adjustment of curing profiles and fabric patterns informed by the thermochemical behavior of materials. The methodology proposed in this study facilitates the strategic optimization of curing properties, fabric characteristics, and manufacturing parameters, enabling effective PID control. Furthermore, this study offers valuable insights into enhancing the design and manufacturing processes of aerospace composite structures, ensuring greater structural integrity, dimensional stability, and overall performance.

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No datasets were generated or analysed during the current study.

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Acknowledgements

This work was supported by the Technology Innovation Program (RS202300257079, Development for high stiffened clean wing structure) funded by Korea government (KASA, Korea AeroSpace Administration). This work was also supported by the (National Research Foundation of Korea NRF) grant funded by the Korea government (MSIT) (No. RS-2022-NR070875).

Funding

This study was funded by Korea government (KASA, Korea AeroSpace Administration) (No. RS202300257079) and the Korea government (MSIT) (No. RS-2022-NR070875).

Author information

Authors and Affiliations

  1. Department of Aerospace and Mechanical Engineering, Korea Aerospace University, Goyang-si, 10540, Gyeonggi-do, Republic of Korea

    Dong-Hyeop Kim & Sang-Woo Kim

  2. Department of Aeronautical and Astronautical Engineering, Korea Aerospace University, Goyang-si, 10540, Gyeonggi-do, Republic of Korea

    Sang-Woo Kim

  3. Research Institute for Aerospace Engineering and Technology, Korea Aerospace University, Goyang-si, 10540, Gyeonggi-do, Republic of Korea

    Dong-Hyeop Kim & Sang-Woo Kim

  4. Commercial Aircraft Design Team, Korea Aerospace Industries, LTD, Sacheon-si, 52529, Gyeongsangnam-do, Republic of Korea

    Tae Su Kim

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  1. Dong-Hyeop Kim
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  2. Sang-Woo Kim
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Contributions

D.H. Kim wrote the main manuscript under the supervision of S.W. Kim, and T.S. Kim revised the manuscript. All authors reviewed the manuscript.

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Correspondence to Sang-Woo Kim.

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Kim, DH., Kim, SW. & Kim, T.S. Prediction of process-induced deformation in CFRP multispar flaps using sequentially coupled thermomechanical analysis considering fabric patterns and stacking sequences. Adv Compos Hybrid Mater (2026). https://doi.org/10.1007/s42114-026-01714-w

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  • Received: 04 February 2025

  • Revised: 29 June 2025

  • Accepted: 20 February 2026

  • Published: 14 March 2026

  • DOI: https://doi.org/10.1007/s42114-026-01714-w

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Keywords

  • Polymer-matrix composite
  • Woven textile composite
  • Effective material property
  • Curing process
  • Process-induced deformation (PID)
  • Finite element method (FEM)

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