New approaches to composite metal joining

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dc.contributor.advisorColegrove, Paul A.
dc.contributor.advisorAyre, David
dc.contributor.authorJoesbury, Adam Michael
dc.date.accessioned2016-06-23T14:29:16Z
dc.date.available2016-06-23T14:29:16Z
dc.date.issued2015-11
dc.description.abstractThis thesis explores new methods for achieving load-carrying joints between the dissimilar materials of continuous fibre reinforced polymer matrix composites and structural metals. The new composite-to-metal joining methods investigated in this work exploit the metal-to-metal joining techniques of arc micro-welding, resistance spot welding, and metal filler brazing, to form novel micro-architectured metal adherends that can be used for enhanced composite-to-metal joining. Through a combination of equipment instrumentation and metallographic inspection of fabricated prototype joints, understanding is gained of how materials respond when processed by manufacturing techniques that have not previously been exploited for dissimilar material joining. Mechanical testing of prototype joints; both to ultimate loading strength and partial failure states, with subsequent inspection of specimens and comparative performances evaluation enabled joining performance characterisation of the new joining methods. Key results include: the identification of micropin reinforced adhesive joints to exhibit pseudo-ductile failure characteristics, resistance spot weld reinforcement of adhesive joints to boost bonding performance, and the use of a polymer infused metal foam to overcome difficulties of thermoplastic to metal adhesion. Through this work knowledge of how novel micro-architectures reacted under mechanical loading enabled insights to be gained into how perceived manufacturing defects can benefit joining performance. Such examples include, localised material weakness that lead to global pseudo-ductile failure behaviour, and low-strength secondary joining mechanisms boosting primary load transfer systems. By comparison of the diverse joining methods investigated in this work, trends were identified that suggest joining performance between the two dissimilar materials is improved by increasing the direct interaction between the composite reinforcement fibres and the metal structure. It is demonstrated that joining improvements are gained by forming mechanical connections between metals and composite precursory material before the final manufacturing process of the composite.en_UK
dc.identifier.urihttp://dspace.lib.cranfield.ac.uk/handle/1826/10009
dc.language.isoenen_UK
dc.publisherCranfield Universityen_UK
dc.rights© Cranfield University, 2015. All rights reserved. No part of this publication may be reproduced without the written permission of the copyright holder.en_UK
dc.subjectDissimilaren_UK
dc.subjectmaterialsen_UK
dc.subjectcarbon fibreen_UK
dc.subjectsteelen_UK
dc.subjectaluminiumen_UK
dc.subjecttitaniumen_UK
dc.subjectepoxyen_UK
dc.subjectweldingen_UK
dc.subjectbrazingen_UK
dc.subjectmicropinen_UK
dc.subjectbondingen_UK
dc.subjectinterlockingen_UK
dc.subjectinfusionen_UK
dc.subjectfoamen_UK
dc.subjectthermosettingen_UK
dc.subjectthermoplasticen_UK
dc.subjectresistance-spoten_UK
dc.subjectprepregen_UK
dc.subjectinfusionen_UK
dc.subjectmicro-architectureen_UK
dc.subjectinterleaveden_UK
dc.subjectthrough-thicknessen_UK
dc.subjectmechanicalen_UK
dc.subjectstructuralen_UK
dc.subjectreinforcementen_UK
dc.subjectfailsafeen_UK
dc.titleNew approaches to composite metal joiningen_UK
dc.typeThesis or dissertationen_UK
dc.type.qualificationlevelDoctoralen_UK
dc.type.qualificationnamePhDen_UK

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