Hybrid Ti-C/PEKK Joining

Efficient Co-Molding of Titanium – C/PAEK joints (ECOMOLD)

2018-2022

Summary:

In the development of lighter structural composite structures, metal inserts present an efficient way of load introduction into thermoplastic composite components. The inserts can be co-molded during thermoplastic composite manufacturing, providing a cost-effective integrated production process. The behavior of the hybrid joint is key to the overall performance of the structure. Bond development between metal and composite is governed by several effects, i.e. mechanical interlocking, physical adhesion and, if possible, chemical bonding. The effect and magnitude of the contribution of the latter two to the overall hybrid bond performance is currently not well understood, despite it being of pivotal importance for the development of hybrid bonds that fail cohesively. Thus, the primary aim of this project is to optimize the hybrid joint, based on a proper understanding of mechanisms governing the hybrid interface development and performance. In this, the research proposed focuses on Ti-6Al-4V – C/PAEK bonds, being typical aerospace materials. Progress will be realized at different length scales:

1.    On the macromolecular and nano scale, the physicochemical state of the bond line, i.e. the metal and the polymer interphase, will be carefully characterized and optimized.

2.    On the microscale, the insert's surface texture will be optimized using numerical simulation methods and experimental validation.

3.    On an engineering or macro scale, a simulation model will be developed that predicts insert performance; including the aforementioned mechanisms on the smaller scale as well as the post-manufacturing stress state in the analysis.

 At the end of the project, the results of the research will be implemented in a software tool that enables the user to analyse a realistic hybrid joint, so on joint scale, as used in the aerospace industry and to optimize it in terms of geometric design and surface texture for certain external loading conditions.

PARTNERS:

-        Industrial partner: ThermoPlastic composites Research Center

-        National subsidy via NWO.


Staff: