Fundamentals of selected aspects of deformation characteristics of adhesive- bonded joints and metal-adhesive interfaces
Deformation characteristics of adhesive bonded joints and metal adhesive interfaces
DEFORMATION↗
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Functional group activation and coupling agent migration induced by plasma treatment in adhesive for enhanced toughness of metal-composite joints
Commercial adhesive paste was additionally activated using low-power oxygen plasma with different plasma exposure durations to investigate its interfacial bonding contribution in adhesively-bonded Aural-5/CFRP-PA6 double cantilever beam (DCB) joints with plasma-treated adherends. The plasma-treated adhesive showed enhanced functional peak intensities in Fourier transfer infrared spectroscopy (FTIR) as plasma exposure time was increased, and some degree of oxidation was also detected via X-ray photoelectron spectroscopy (XPS). A small molecule, dicyandiamde (coupling agent) in adhesive was migrated to adhesive layer, where double concentration of coupling agent was detected after 10 minutes of plasma treatment. As a result, characterization of the adhesive/CFRP-PA6 interface after DCB fracture showed additional chemical bonds formed through amine-initiated epoxy ring opening polymerization, as well as amide bonds and ester bonds. In conclusion, these additional bonds at the adhesive/CFRP-PA6 interfaces led to significantly increased failure extensions and fracture energies of the joints as the plasma exposure time on the adhesive increased, compared to the joints with plasma-treated adherends but non-plasma-treated adhesive as commonly seen in the literature.
36 MATERIALS SCIENCE↗
Evaluation of the Corrosion of Metallic Fastener Joints in Composite Materials Immersed in Seawater
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Presuel-Moreno, Francisco [FAU]↗
Bonded composite to metal scarf joint performance in an aircraft landing gear drag strut
The structural performance of a boron-epoxy reinforced titanium drag strut, which contains a bonded scarf joint and was designed to the criteria of the Boeing 747 transport, was evaluated. An experimental and analytical investigation was conducted. The strut was exposed to two lifetimes of spectrum loading and was statically loaded to the tensile and compressive design ultimate loads. Throughout the test program no evidence of any damage in the drag strut was detected by strain gage measurements, ultrasonic inspection, or visual observation. An analytical study of the bonded joint was made using the NASA structural analysis computer program NASTRAN. A comparison of the strains predicted by the NASTRAN computer program with the experimentally determined values shows excellent agreement. The NASTRAN computer program is a viable tool for studying, in detail, the stresses and strains induced in a bonded joint.
Howell, W. E.↗
Preliminary study on pressure brazing and diffusion welding of Nb-1Zr to Inconel 718
Future space power systems may include Nb-1Zr/Inconel 718 dissimilar metal joints for operation at 1000 K for 60,000 h. The serviceability of pressure-brazed and diffusion-welded joints was investigated. Ni-based metallic glass foil filler metals were used for brazing. Ni and Fe foils were used as diffusion welding inter-layers. Joint soundness was determined by metallographic examination in the as-brazed and as-welded condition, after aging at 1000 K, and after thermal cycling. Brazed joints thermally cycled in the as-brazed condition and diffusion-welded joints were unsatisfactory because of cracking problems. Brazed joints may meet the service requirements if the joints are aged at 1000 K prior to thermal cycling.
Moore, T. J.↗
Measurements of thermal contact conductance in a vacuum
Thermal interface conductance measurements on small metallic joints in vacuum environment
MEASURING APPARATUS↗
Finite element thermal-structural modeling of orbiting truss structures
A description of an integrated finite element (FE) thermal-structural approach for accurate and efficient modeling of large space structures is presented. A geometric model with a common discretization for all analyses is employed. It uses improved thermal elements and the results from the thermal analysis directly in the structural analysis without any intervening data processing. The differences between the conventional FE approach as implemented in large programs and an integrated FE approach currently under development are described. Considerations for thermal modeling of truss members is discussed and three thermal truss finite elements are presented. The performance of these elements was evaluated for typical truss members neglecting joint effects. A simple truss with metallic joints and composite members was studied to evaluate the effectiveness of the approach for realistic truss designs. A study of the effects of aluminum joints on the thermal deformations of a simple, plane truss with composite members showed that joint effects may be significant. Further study is needed to assess the role of joint effects on the deformation of large trusses.
Thornton, E. A.↗
A study of embedment and other metallurgical and mechanical characteristics of cross-wire resistance welds.
Cross-wire resistance welded metal joints for aerospace electronic packing assemblies, investigating embedment, mechanical strength and materials evaluation
FRACTURE RESISTANCE↗
Evaluation of a high temperature adhesive for fabricating graphite/PMR-15 polyimide structures
Tests are conducted to measure shear strength, shear modulus and flatwise tensile strength of the A7F (amide-imide modified LARC-13) adhesive system. An investigation is also conducted to determine the effect of geometric material parameters, and elevated temperature on the static strength of standard joints. Single-lap and double-lap composite joints, and single, double and step lap composite to metal joints are characterized. A series of advanced joints consisting of preformed adherends, adherends with scalloped edges and joints with hybrid interface plies are tested and compared to baseline single and double-lap designs.
Hill, S. G.↗
3D Woven Composite End Ring Structure: Design Development and Verification Testing
The National Aeronautics and Space Administration (NASA) Space Technology and Mission Directorate (STMD) is advancing composite technologies for exploration missions. The Composite Technology for Exploration (CTE) project goal is to advance lightweight joint concepts for Space Launch System (SLS) class structures. To this end CTE is developing and demonstrating a 3D woven carbon /epoxy composite joint design co-bonded in a circumferential end ring configuration, applied to a SLS sized conceptual payload attachment structure. This joint is a lightweight alternative to heavy and costly metallic joints. The 3D woven joint development advances lightweight joint technologies through material and structural design, material and joint analyses, and fabrication, as well as demonstration through building block testing. Prior limited building block tests are mentioned. In this paper, new sub-element-scale test results are described that demonstrate the structural capability well beyond design limit load. Then, results for a sub-component test article with a 889 mm joint subjected to combined loads are presented.
Kenneth N Segal↗
Optimized Bolted Joint
Computer technique aids joint optimization. Load-sharing between fasteners in multirow bolted composite joints computed by nonlinear-analysis computer program. Input to analysis was load-deflection data from 180 specimens tested as part of program to develop technology of structural joints for advanced transport aircraft. Bolt design optimization technique applicable to major joints in composite materials for primary and secondary structures and generally applicable for metal joints as well.
Hart-Smith, L. J.↗
Method of cold welding using ion beam technology
A method for cold welding metal joints is described. In order to remove the contamination layer on the surface of the metal, an ion beam generator is used in a vacuum environment. A gas, such as xenon or argon, is ionized and accelerated toward the metal surface. The beam of gas effectively sputters away the surface oxides and contamination layer so that clean underlying metal is exposed in the area to be welded. The use of this method allows cold welding with minimal deformation. Both similar and dissimilar metals can be cold welded with this method.
Sater, B. L.↗
A Compendium of Brazed Microstructures For Fission Power Systems Applications
NASA has been supporting design studies and technology development for fission-based power systems that could provide power to an outpost on the Moon, Mars, or an asteroid. Technology development efforts have included fabrication and evaluation of components used in a Stirling engine power conversion system. This investigation is part of the development of several braze joints crucial for the heat exchanger transfer path from a hot-side heat exchanger to a Stirling engine heat acceptor. Dissimilar metal joints are required to impart both mechanical strength and thermal path integrity for a heater head of interest. Preliminary design work for the heat exchanger involved joints between low carbon stainless steel to Inconel 718, where the 316L stainless steel would contain flowing liquid metal NaK while Inconel 718, a stronger alloy, would be used as structural reinforcement. This paper addressed the long-term microstructural stability of various braze alloys used to join 316L stainless steel heater head to the high conductivity oxygen-free copper acceptor to ensure the endurance of the critical metallic components of this sophisticated heat exchanger. The bonding of the 316L stainless steel heater head material to a copper heat acceptor is required to increase the heat-transfer surface area in contact with flowing He, which is the Stirling engine working fluid.
Locci, Ivan E.↗
Mars Atmosphere Effects on Arc Welds: Phase 1
NASA has been unprecedented in achieving its goals related to space exploration and furthering the understanding of our solar system. In keeping with this trend, NASA's current mission is to land a team of astronauts on Mars and return them safely to Earth. In addition to comprising much of the structure and life support systems that will be brought to Mars for the habitat and vehicle, titanium and aluminum can be found and mined on Mars and may be used when building structures.Where metals are present, there will be a need for welding capabilities. For welds that need to be made quickly and are located far from heavy resistance or solid state welding machinery, there will be a need for basic arc welding. Arc welding has been a major cornerstone of manufacturing throughout the 20th century, and the portability and capability of gas tungsten arc welding (GTAW) will be necessary for repair, manufacturing, and survival on Mars. The two primary concerns for welding on Mars are that the Martian atmosphere contains high levels of carbon dioxide (CO2), and the atmospheric pressure is much lower than it is on Earth. The high levels of CO2 in the Martian atmosphere may dissociate and produce oxygen in the arc and therefore increase the risk of oxidation. For simplification, atmospheric pressure will not be taken into account for this experiment. For survival on Mars during this mission, the life support and water filtration systems must be kept operational at all times. In order to ensure that water filtration systems can be repaired in the event of an emergency, it is very important to have the capability to weld. The Orion capsule and Mars lander must also remain operational throughout the duration of the mission to ensure the safe return of the astronauts on the mission to Mars. A better understanding of welding in a Mars environment is important to ensure that repair welds are possible if the Orion capsule/Mars lander or water filtration system is damaged at any point while on the surface of Mars. The Orion capsule is made primarily of AA2219-T87, and the water filtration system is primarily Ti-6Al-4V, so the effect of the Mars environment on welding those materials must be known to reduce potential mission risk. GTAW is a portable process that can weld a versatile group of metals, so it has many potential applications for welding on Mars. Thus, missions to colonize Mars will depend on the capability to weld a strong, leak-tight joint. Metals are also likely to be used in support structures made of a lightweight and durable material. For this reason, it is important to understand the implications of welding in a Mars environment. A comparison of the Martian and terrestrial atmospheres are provided in table 1. Based on the elemental compositions, simulation of the Martian atmosphere can be made using primarily CO2 gas.
Courtright, Z. S.↗
Measurements of thermal-contact conductance between dissimilar metals in a vacuum.
Measuring thermal contact conductance of various dissimilar metal joints in vacuum for testing Saturn electronic components
ELECTRONIC EQUIPMENT TESTING↗
Investigation of static and cyclic bearing failure mechanisms for GR/EP laminates
Static, cyclic load (fatigue), and residual strength testing of graphite-epoxy (GR/EP) and aluminum pin bearing joints was completed to study bearing failure mechanisms. Parameters investigated included static strength, failure mode, fatigue life, hole growth, joint stiffness, and residual strength. Comparative evaluation of these results show that the MIL-HDBK-5 convention for the definition of bearing strength can be used for GR/EP materials while maintaining the same, or improved, level of structural integrity shown for metal joints.
Walter, R. W.↗
Investigation Leads to Improved Understanding of Space Shuttle RSRM Internal Insulation Joints
The Space Shuttle Reusable Solid Rocket Motor (RSRM) uses an internal insulation J-joint design for the mated insulation interface between two assembled RSRM segments. In this assembled (mated) segment configuration, this J-joint design serves as a thermal barrier to prevent hot gases from affecting the case field joint metal surfaces and O-rings. A pressure sensitive adhesive (PSA) provides some adhesion between the two mated insulation surfaces. In 1995, after extensive testing, a new ODC-free PSA (free of ozone depleting chemicals) was selected for flight on RSRM-55 (STS-78). Post-flight inspection revealed that the J-joint, equipped with the new ODC-free PSA, did not perform well. Hot gas seeped inside the J-joint interface. Although not a flight safety threat, the J-joint hot gas intrusion on RSRM-55 was a mystery to the investigators since the PSA had previously worked well on a full-scale static test. A team was assembled to study the J-joint and PSA further. All J-joint design parameters, measured data, and historical performance data were re-reviewed and evaluated by subscale testing and analysis. Although both the ODC-free and old PSA were weakened by humidity, the ODC-free PSA strength was lower to start with. Another RSRM full-scale static test was conducted in 1998 and intentionally duplicated the gas intrusion. This test, along with many concurring tests, showed that if a J-joint was 1) mated with the new ODC-free PSA, 2) exposed to a history of high humidity (Kennedy Space Center levels), and 3) also a joint which experienced significant but normal joint motion (J-joint deformation resulting from motor pressurization dynamics) then that J-joint would open (allow gas intrusion) during motor operation. When all of the data from the analyses, subscale tests, and full-scale tests were considered together, a theory emerged. Most of the joint motion on the RSRM occurs early in motor operation at which point the J-joints are pulled into tension. If the new PSA has been weakened due to humidity, then the J-joint will partially pull apart (inboard side), and the J-joint surfaces will be charred by exposure to hot gases. After early operation, a J-joint that has been pulled apart will come back together as the J-joint deformation decreases. This J-joint heating event is relatively short and occurs only during the first part of motor operation. Internal instrumentation was developed for another full-scale static test in February 2000. The static test instrumentation did indeed prove this theory to be correct. Post-test inspection revealed very similar charring characteristics as observed on RSRM-55. This experience of the development of a new PSA, its testing, the RSRM-55 flight, followed by the J-joint investigation led to good 'lessons learned' and to an additional fundamental understanding of the RSRM J-joint function.
McWhorter, Bruce B.↗
Current-Activated Reactive Ultrafast Joining (CARUJ)
We have demonstrated Current Activated Reactive Ultrafast Joining (CARUJ) as a novel approach for rapid fabrication of similar and dissimilar materials, such as ceramic-ceramic and ceramic-metal joint assemblies. The CARUJ technology utilizes resistive heating of carbon-based materials to apply localized heat at, (through or around) joint zones at rates of 10 1 -10 2 ˚C/min, enabling joining at time scales considerably shorter (several minutes as opposed to hours) than conventional approaches for similar systems. Herein, we present our findings while evaluating the CARUJ concept. Three methods of heat application were evaluated: (i) using carbon joule heating elements to apply heat directly through the joint interface; (ii) using flexible joule heating elements to locally apply heat around the assembly interface; and (iii) non-contact heating of the joint assembly using inductive power. Schemes (ii) and (iii) proved to be the most effective in producing mechanically sound reliable joints. We demonstrated single-step fabrication of dense SiC-SiC joints with a Si- SiC interface using minimal pressure (1–2 MPa) in under 30 minutes. Measured average joint strengths of about 15 MPa are initially achieved for joined bodies when tested in single lap offset (SLO) compressive shear, while tuning of the interfacial composition along with a reduction in interlayer thickness, results in improved joint strengths of approximately 43 MPa. We further demonstrated SiC-SiC joining using Active Brazing Alloys (ABAs) proof of concept joining of tubular geometries. The versatility of CARUJ is demonstrated by utilizing non-contact heating via induction, to join dissimilar materials systems of SiC, SS316 and MAX phase ceramics with ABA interlayers. The localized and rapid heat application realizes a versatile material joining technique that can be extended for joining components at the plant site.
36 MATERIALS SCIENCE↗