Customisable Hybrid Truss and Novel Joining Concepts · PDF fileComposites and Metals - Integration challenges ! ... Joining Advanced Metal Interfaced Composites (JAMICOMPS) Technologies

© HiETA Technologies Ltd 2016 - The information in this presentation contains confidential and/or privileged material. You are hereby notified that any disclosure, copying, distribution or use of the information contained herein or in any attachment is strictly prohibited.

Customisable Hybrid Truss and Novel Joining Concepts

Desi Bacheva and Ben Farmer

[email protected] [email protected]

© HiETA Technologies Ltd 2016

Outline

!   Introduction to Additive Manufacturing (AM) and HiETA Technologies

!   Composites and Metals - Integration challenges

!   Lightweight Hybrid Truss Structures - Development and opportunities

!   Joining Advanced Metal Interfaced Composites (JAMICOMPS) Technologies – Novel hybrid joining concepts


Who We Are

!  Specialists in thermal management and lightweighting solutions enabled by Additive Manufacturing

!  Established four years ago with approximately 25 staff !  Technology Centre with R&D and manufacturing cells at

Bristol and Bath Science Park

!  Number of past and current Innovate UK and CDE projects for automotive, motorsport, defence and aerospace sectors


HiETA Vision

RealiseCO2reduc/onvialightweigh/ngandefficiencythroughtheuseofAddi/veManufacturing

Productdesignandmanufacturingreadinessservicesfromearlystagedesign,processdevelopmentandearlystagemanufacturingsupport

tofacilitateinformedclients&users


What is AM?

!  Additive Manufacturing – not subtractive. Tends to build from fine atomised powder feedstock.

!  “3D printing” !  Many processes

!  Many acronyms!

!  We deal predominantly with METAL POWER BED FUSION process


Why AM?

Componentintegra-on

Increasedperformance

Improvedpackaging

ReducedweightReducedlead-me


Product Portfolio

Customerrequirementsconvertedintoinnova/vesolu/ons

Micro Power Generation

Waste Heat Recovery

Highly Efficient ICE

Lightweighting and Optimisation

Micro Gas Turbine

Fuel cell cooling

Inverted brayton cycle system

Brayton cycle scroll engine

Turbo machinery

Reciprocating engine

Cooled turbine wheels (CM247)

Cooled compressor

Hollow head valve

Cooled exhaust

Lattice architectures

Thrust nozzle Turbine nozzle

Hybrid Truss Structures

Novel composite-to-metal joints

Cuboid

Recuperator

Annular

Recuperator


Composites and Metals

Metals Easily shaped to create geometric complexity Isotropic properties accommodate complex multiaxial loads

Composites Work best in simple shapes but difficult to form complex geometries Anisotropic properties better suited to simple (in-plane) loads

Hybrid Structures Mechanical, adhesive and hybrid joining Material and thermal property mismatch Different failure behavior Corrosion and environmental degradation

Lower leg of HyQ robot


R160 Concept

Challenge:Howtomakeagreatjoint?

Titaniumnodes

Roll-wrappedUDpre-pregcarbontubes

Bo@ombracketcentricDW6suspensiondesign

Secondarybondedjoint

Lightweight Hybrid Truss

h@ps://dirtmountainbike.com/bike-reviews/trail-enduro-bikes/specialized-enduro-29-six-ways-three-wheels-sizes.html

Mul-pleloadinputsappliedindifferentloadcasecombina-ons

Loadscoupletostructureinareasofgeometriccomplexity

resulNnginout-of-planestress


Parametric CAD


Double lap shear (π joint)

Xmm

Run-outtoasthinaspossiblesecNon.

Applyradius.

AllowsplurgefilletbutcleanaddiNonalresidueimmediately

ymmnominalbondlinethickness

Degreasepriortoabrading

Twopartpasteadhesiveappliedtobo@omofPiclevis.Morereliableapproachtoensurecoverageandminimiseporosity

thantheapplicaNonoffilmadhesive.

Adhesive

InserNonsqueezeflow

method

Degrease

!  Structurally efficient !  Robust

!  Accepting of cost effective pre-preg roll-wrapped tube

!  Easy to assemble

Joint Solution


Joint solution: Double lap shear (π joint)

Doublelapshear(πjoint)

Structurallyefficient

•  WeightefficientadhesivelybondedsoluNon•  Highbondsurfacearea•  Avoidopen-andfilled-holesincomposite

Robust

•  Doublelaparchitectureminimisesoutofplanestresses.•  RoughnessresulNngfromAMprocessprovidessuitablesurface.•  HighaspectraNopossibleasaresultofAMprocess•  Reliableadhesivecoverage

AccepNngofcosteffecNvepre-pregroll-wrappedtube

•  AccepNngofhardsubstrates

Easytoassemble

•  MinimalsurfacepreparaNon•  InserNonsqueezeflowmethod•  Friendlytollerancing


Titanium Additive Manufacturing

Customgeometry

Highaspect-doublelapshear

joints

Minimumsupportstructures

Surfaceroughnessaids

bonding

AccommodaNngofvariaNonin

othertechnologies

PartnesNng

RapidremovalfrombuildplateShortleadNme


Testing of assembly

Testvalida8on–ENISOBS4210-6:2014


Rider testing

© HiETA Technologies Ltd 2016 - The information in this presentation contains confidential and/or privileged material. You are hereby notified that any disclosure, copying, distribution or use of the information contained herein or in any attachment is strictly prohibited.

Joining Advanced Metal Interfaced Composites (JAMICOMPS)

CDE 42249 project


JAMICOMPS !  Aim

To develop novel in-built internal mechanical interlocking strategies that can replicate the need for a physical mechanical fixing (i.e. a bolt) in an adhesively bonded/co-bonded configuration

!  Objectives

Ø To attain enhanced interfacial adhesion and damage tolerance of hybrid joints

using metal AM and composite manufacturing techniques

Ø To improve the integration and structural longevity of hybrid components whilst reducing weight and cost


JAMICOMPS Examples of Through-Thickness Reinforcing Hybrid Joining

HYPER Joints

COMELD Joints


JAMICOMPS !  Benefits

Ø Reduction in shear and peel stresses due to increased bonded surface area without having a larger overlap area

Ø Enhanced damage tolerance by the creation of tailored interfaces for optimum and controlled load path

Ø Decrease in the mismatch by the creation of a transition zone in the joint Ø Through-thickness topological interlocking increasing the delamination resistance

!  Challenges

Ø Inspection and repair Ø Dimensional stability and tolerancing of the metal adherents manufactured by

SLM Ø Manufacturing challenges associated with the integration of the metal and

composite phases due to the high level of novelty and complexity


JAMICOMPS !  Development of several key concepts for hybrid joints

!  Materials – Gurit SE70 epoxy prepreg and Ti6Al4V titanium alloy

!  Experimental approach - double cantilever beam (DCB) and lap shear tests

! Downselection to one concept will be based on performance, manufacturability, flexibility and cost

!  Integration into an industry relevant demonstrator concept – T-joint pull off test

JAMICOMPS joining technology

4 mm

4 mm4 mm

50 mm

86 mm

T-joint configuration

Composite

TitaniumPre-crackRegion

Experimental DCB setup


DCB Test Results Baseline with adhesive film Concept 1 Concept 2

Concept 3

Concept 5

Concept 4

0

100

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0 5 10 15 20 25 30

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, N

Extension, mm

1_1 Concept 2

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1_2 Concept 4 - Combined

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1_1 Concept 5 - Combined

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1_1 Concept 3

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2_2 Concept 1


R-curve plots

Crack length (mm) Interlaminar fracture toughness, GIc

Benchmark Concept 1 Concept 5 50 455 175 143

60 876 948 932

65 1030 1370 1460

70 1101 1875 1701

80 1212 3140 2907

0

100

200

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, N

Extension, mm

2_2 Concept 1

1_1 Concept 5

4_2 Benchmark hybrid w/SA70 film

0

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4500

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0 10 20 30 40 50 60 70 80 90 100 110

GIc

, J/m

2

Crack length, mm

2_2 Concept 1

1_1 Concept 5

4_2 Benchmark hybrid w/SA70 film

Concepts 1 and 5


JAMICOMPS - Summary !  Performance

Two to three fold increase in load carrying capability of DCB specimens with integrated JAMICOMPS concepts compared to baseline DCB.

Concepts with strong interface exceeding the actual composite strength.

The steep R-curve profiles show a significant increase in the fracture toughness values indicating that the mechanical interlocking enhances the interfacial strength of the hybrid DCB specimens.

!  Current work

All composite DCB test with titanium inserts, lap shear test, development of FE model for the simulation of Mode I fracture toughness, and manufacture and test of T-joint configuration.


Conclusion

!  Hybrid Truss

Ø Key elements is the intergration of cost effective composite with AM nodes with structurally efficient double lap shear joints.

Ø Parametrically-driven design depending on the loading case and size envelope.

!  JAMICOMPS Technology

Ø Extending JAMICOMPS Technology to other materials systems, i.e. thermoplastic polymer composites, aluminum alloys.

Ø Manufacturing/assembly/integration.

!  Technology Exploitation

Ø Are there existing application challenges that could benefit from Hybrid Truss and JAMICOMPS technologies or derivatives of this work?


THANK YOU

Documents

Customisable Hybrid Truss and Novel Joining Concepts · PDF fileComposites and Metals - Integration challenges ! ... Joining Advanced Metal Interfaced Composites (JAMICOMPS) Technologies