Joining and Integration of Advanced and Specialty Materials: Joining and Integration of Advanced and Specialty Materials
Sponsored by: ACerS Engineering Ceramics Division
Program Organizers: Milena Salvo, Politecnico di Torino; Rajiv Asthana, University of Wisconsin; Valentina Casalegno, Politecnico di Torino; Monica Ferraris, Politecnico di Torino - Italy; Michael Halbig, NASA Glenn Research Center; Dietmar Koch, University of Augsburg; Hans-Peter Martin, Fraunhofer-Institut für Keramische Technologien und Systeme IKTS; Michael Reece, Queen Mary, University of London; Peter Tatarko, Institute of Inorganic Chemistry Slovak Academy of Sciences; Fabrizio Valenza, National Research Council, Institute of Condensed Matter Chemistry and Technologies for Energy
Monday 8:00 AM
November 2, 2020
Room: Virtual Meeting Room 23
Location: MS&T Virtual
8:00 AM
Introductory Comments: Joining and Integration of Advanced and Specialty Materials: Monica Ferraris1; 1Politecnico di Torino
Introductory Comments
8:05 AM Keynote
Adhesive Bonding of Carbon Fiber Reinforced Polymers to Dual Phase 980 Steel: Yong Chae Lim1; Jian Chen1; Ngoc Nguyen1; Yuan Li1; Amit Naskar1; Zhili Feng1; 1Oak Ridge National Laboratory
Joining of carbon fiber reinforced polymer (CFRP) to advanced high strength steel (AHSS) has a great potential for lightweight multi-materials vehicle applications. Although adhesive bonding is one of common joining processes, there has been a limited understanding of adhesive bonding for metal to CFRP. In the present work, we present adhesive bonding of dual phase (DP) 980 steel to thermoplastic and thermoset CFRP. Surface chemistry and roughness for the selected adherends were characterized by advanced analytical techniques. Structural adhesives with different moduli were employed to study the joining strength of CFRP and DP980 by a single lap shear strength. Furthermore, surface engineering technique was applied on the thermoplastic CFRP to improve bonding strength. Digital image correlation technique was developed to study localized adhesive deformation between adhesive and adherend during lap shear testing.
8:45 AM
Controlling the Formation of Intermetallic Compounds in TLP Joining of Grade-2 Titanium Alloy: AHM Esfakur Rahman1; 1Pennsylvania State University, Harrisburg
Transient Liquid Phase (TLP) bonding is primarily a solid-state diffusion joining process. The joining temperature is below the melting point of parent alloys while higher than the melting point of interlayer materials. As a result, there is no heat affected zones (HAZ) in TLP bonded joints. However, interlayer materials forms intermetallics almost all the times in the microstructure of the joint area. If not controlled properly, these intermetallics becomes detrimental and reduces the strength of the joint significantly. This research focuses how the formation of intermetallics and their distribution in the microstructure can be controlled. The interlayer used was 99.99% pure Copper (Cu) foil. The joining temperature, time, interlayer thickness, and roughness of the faying surfaces were optimized to obtain the best possible microstructures. SEM images and point EDS were used to investigate the microstructure and chemical composition of the bonded area.
9:05 AM
Effects of Strength Overmatching on the Assessment of Toughness in Hybrid Laser Arc Welded High Strength Steel: Daniel Bechetti1; Matthew Sinfield1; Maximilian Kinsey1; Nathan Korinchak1; 1NSWC Carderock Division
High energy density joining processes are attractive to shipbuilders because they minimize distortion and reduce construction costs. They also produce hard, narrow fusion zones that complicate mechanical evaluation. Traditional weldment mechanical property acceptance through the Charpy V-notch test is made possible by decades of test records correlated to fracture toughness testing and validation through in-service performance. Charpy testing of hybrid laser arc weld (HLAW) fusion zones to evaluate quality conformance is difficult because of fracture path deviation into the base metal or heat affected zone. This study reports on methods used to assess weld metal toughness in HLAWs fabricated using high strength ship steels. The discussion will include pitfalls associated with Charpy and fracture toughness testing of HLAWs, the establishment of relationships between modified and standard Charpy testing for evaluating HLAW performance, and miniature tensile testing of narrow fusion zones to characterize the degree of strength mismatch in these joints.
9:25 AM
Functionally-graded Interlayers for Enhanced Divertor/Heatsink Bonding: Huong Le1; Kamyar Ahmadi2; Brian Skinn1; Stephen Snyder1; Ed Liguori3; Timothy Hall1; 1Faraday Technology Inc; 2University of Houston; 3Braze Engineering and Design
At present, an international consortium is engaged in a project that involves construction of an historical large-scale, energy-positive fusion reactor. Among the numerous components undergoing development and refinement are the divertor modules situated at the bottom of the vacuum vessel, which extract heat and ash produced by the fusion reaction, minimize plasma contamination, and protect the surrounding walls from thermal and neutronic loads. In order to provide the high heat transfer capacity necessary to handle the anticipated flux from the fusion plasma, it is planned to use copper alloy heatsinks in combination with tungsten plasma-facing components (PFCs). However, the dramatic mismatch in coefficients of thermal expansion between tungsten and copper represents a significant outstanding challenge for this combination of materials. In this communication, we describe the potential for economical, scalable pulsed FARADAYIC® ElectroDeposition of functionally-graded interlayers for enhanced PFC/heatsink bonding properties.
9:45 AM
Development of Interlayer Technology to Join Advanced and Dissimilar Materials: Bryan Lara1; Rafael Giorjao1; Antonio Ramirez1; 1The Ohio State University
The need for lightweight, fuel efficient vehicles is becoming increasingly common in the automotive industry. The implementation of advanced high strength steels (AHSS) and aluminum alloys to body in white designs promote the ability to use materials with better strength to weight ratios than previous generation materials. Resistance spot welding AHSS to Al brings forth its own set of challenges but the ability to use new techniques can help improve the weldability issues of these joints. This two-part study investigates the use of interlayer technology to improve the weldability and mechanical performance of AHSS-AHSS and AHSS-Al joints. The interlayer deposition, RSW parameters and mechanical performance of these joints will be presented.
10:05 AM
Spark Plasma Joining of Ultra-high Temperature Ceramics: Ambreen Nisar1; Cheng Zhang1; Benjamin Boesl1; Arvind Agarwal1; 1FIU
Ultra-high temperature ceramics (UHTCs) are ideal candidates for advanced thermal protection system (TPS). Widespread use of UHTCs demands the effective ways of joining to overcome the problems associated with the fabrication of complex shaped components. For joining to be a preferred method of fabricating complex structures, the UHTC-UHTC joint must exhibit close to similar microstructure and mechanical properties as that of the parent material. To integrate UHTCs for TPS, we choose to investigate a new method of rapidly joining UHTCs by spark plasma sintering (SPS) technique. In this regard, the pre-sintered TaC and HfC, processed using SPS at 1850 °C were then put together and joined (at the same conditions) without any filler material. Well-bonded TaC-HfC interface was observed at the joint. In addition, the mechanical strength at the interface is similar when compared with that of the monoliths, i.e. TaC and HfC.