USE OF CFRP COMPOSITES AND NEW JOINING PROCESSES IN AIRCRAFT … · 2018. 8. 11. · N.Z. Borba 3...
Transcript of USE OF CFRP COMPOSITES AND NEW JOINING PROCESSES IN AIRCRAFT … · 2018. 8. 11. · N.Z. Borba 3...
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N.Z. Borba
Natascha Z. Borba
USE OF CFRP COMPOSITES AND NEW JOINING PROCESSES IN AIRCRAFT FUSELAGE
Solid State Joining Processes – WMPMaterials MechanicsInstitute of Materials Research
Composites Europe - Stuttgart – 08.11.2018
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Trend in aircraft design: rational mixture of metal and composites to reduce costs and cope with legislation (ACARE Flightpath 2050- Environmental goals)
INTRODUCTIONHybrid Metal-Polymer Structures in Aircraft Applications
[1]
[1] Airbus FAST57, 2016
Time
Perf
orm
ance
Metallic
structures
Composite
structures
€
Performancekg
Airbus A320
↓ CO2 emissions by 75% per passenger/km
71%
6%10%
Composite
53%
Ti
14%
Al/Al-Li
19%
Composite not yet at
„saturation level“
Airbus A350-XWB
Air vehicles more recyclableSustainable and commercially
viable alternative fuel
Steel
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INTRODUCTIONHybrid Metal-Polymer Structures in Aircraft Applications
Adhesive Bonding
Mechanical Fastening
Riveting, screwing, bolting,
clinching, collar joining
FricRiveting
ICJ
Welding-based Technologies
Ultrasonic
Induction
Resistance
Laser
Friction
Hybrid Technologies
RivbondingWeldingbond
Injection over Molding
Direct Assembly
(Co-Bonding/-Curing)
[*] S.T. Amancio-Filho, J.F. dos Santos, Polym. Eng. Sci., 2008
o Reduced maintenance
o Improved performance
o Cost effective and sustainable joining techniques
Metallic structures:
Friction Stir Welding Refill Friction Stir Spot
Welding Friction Surfacing
Metal-composite structures:
Friction Stir Welding Friction Spot Joining
Requirements: development of new designs and concepts for hybrid structures
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FRICTION-BASED JOINING PROCESSESWMP Demonstrator
Section of fuselage integrating seven innovative joining technologies which aimed to overcome drawbacks of conventional methods for dissimilar materials
Requirements: Materials:
Skin: CF-PEEK, AA2024 (3.1 mm)
Stringer: AA7050
Frame: AA7075
Short
joining
cycles
Defect free
Low
distortion
Improved
mechanical
performance
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FRICTION-BASED JOINING PROCESSESWMP Demonstrator
Friction-based welding processes for aluminum alloys components
Refill Friction Stir Spot Welding
Friction Surfacing
[3] Suhuddin, U. et al, Applied Physics Letters, 2014
[4] Ehrich, J. et al, MSE, 2018
Stationary Shoulder Friction Stir Welding
Bobbin Tool Friction Stir Welding
[1] Barbini, A., PhD Thesis, 2018
[2] Göbel, J., PhD Thesis, 2018
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FRICTION-BASED JOINING PROCESSESWMP Demonstrator
Friction-based joining processes for metal-composite hybrid components
Friction Spot Joining
[1] Manente, N., PhD Thesis, 2018
FSpJFricRiveting
FricRiveting
Frame Stringer Doubler
Friction Riveting
[2] Borba, N.Z., PhD Thesis, 2018
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FRICTION RIVETINGGeneral Aspects
Patented in 2007 by Amancio et al. (EP 1 790 462 B1; US 7 525 149 B2 )
Based on mechanical fastening and friction welding
Prize-winning joining technology
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FRICTION RIVETINGPrinciples of the Process
HZG patent: EP 1 790 462 B1; US 7,575,149 B2
(Amancio-Filho et al.)
Positioning of the joining parts
Rotating rivet insertion &
Polymer melting
Plasticizing of the rivet & Forging
Anchoring &Joint
consolidation
Time
CFRP
CFRP
Metallic rivet
Joining mechanisms: General aspects:
Joining cycles (0.5 to 12.0 s)
No surface preparation
Single side accessibility
Minimum thickness required
Permanent joint[1] Mechanical Anchoring (macro and micro)
[2] Adhesion Forces
5 mm
5 mm[1]
[1]
[2]
5 mm
squeezed material
[2]
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FRICTION RIVETINGIndustrial Transferability of Friction Riveting
Dev
elo
pm
ent
Time
Coupon
Sub-component
Component
Full-scaleScaling-up challenges
[1]
[2]
TRL 5
Engineering challenges
Knowledge gaps:
Joint design Fatigue analysis Joint durability Damage tolerance
TRL 4
5 mm
Case study: Ti6Al4V/ CF-PEEK friction-riveted joints
[1] Eastlake et al., Embry-Riddle Aeronautical University, National Transportation Safety Board, Boeing
[2] Airbus FAST57, 2016
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FRICTION RIVETING - SELECTED RESULTSMechanical Behavior and Damage evolution
Quasi-static mechanical performance
Comparison with reference bolted joints
Fracture micro-mechanisms: definition of failure criteria
135 mm
36
mm
36 mm
Loading direction
5 mm
36
mm
135 mm
Loading direction
30 mm
I.
II.III.
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FRICTION RIVETING - SELECTED RESULTSMechanical Behavior and Damage evolution
Fatigue life
Parameters (STP723/ASTM): R = 0.1, 5 Hz, room temperature, two-parameter Weibull distribution
[2] Bolted and bonded hybrid joints
[1] Aircraft industry requirement
66%
50%
35%
[1] Fatigue & Damage Tolerance Course, AeroStruct (2017)[2] G.Kelly, Composite Structures 72 (2006) 119-129
[2]
[1]
6.2 ± 0.3 kN 5.9 ± 0.3 kN
R-Sq = 89%
After 106 cyclesQuasi-static
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FINAL REMARKS
Concept of metal-composite hybrid aircraft fuselage joined by innovative friction-based joining processes was proven through the WMP demonstrator
Friction Riveting is an alternative, prize-winning joining technique for metal-composite multi-material structures
Similar-to-improved quasi-static and cyclic mechanical performance of friction-riveted joints compared to the stat-of-the-art bolted joints showing potential for future aircraft structural application
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Thank you! (Hall 9, C78)
FOR PEOPLE AND THEIRFUTURE ENVIRONMENT
Natascha Z. Borba
Helmholtz-Zentrum Geesthacht
+49 04152 87-2608
Max-Planck Str. 1
21502 Geesthacht
Acknowledgment