Joining carbon fiber composites and aluminum for lightweight cars and other multi-material high-end products could become less expensive and the joints more robust because of a new method that harnesses a laser’s power and precision.
The process, developed by a team led by Adrian Sabau of the Department of Energy’s Oak Ridge National Laboratory, would replace the practice of preparing the surface of the materials by hand using abrasive pads, grit blasting and environmentally harmful solvents. Using a laser to remove layers of material from surfaces prior to bonding improves the performance of the joints and provides a path toward automation for high-volume use.
“Our technique is vastly superior to the conventional surface preparation methods,” Sabau said. “Combined with the potentially dramatic reduction in the cost of carbon fiber polymer composites, this represents an important step toward increasing the use of this lightweight high-strength material in automobiles, which could reduce the weight of cars and trucks by 750 pounds.”
The surface treatment of aluminum and carbon fiber polymer composite is a critical step in the adhesive joining process, which directly affects the quality of bonded joints. Aluminum surfaces typically contain oils and other contaminants from production rolling operations while carbon fiber surfaces often contain mold releases.
“These surface contaminants affect surface energies and the quality of adhesion, so it is critical that they are removed,” said Sabau, adding that the laser also penetrates into the top resin layer, leaving individual carbon fibers exposed for direct bonding to the adhesive and increasing the surface area for better adhesion.
Test results support Sabau’s optimism as single-lap shear joint specimens showed strength, maximum load and displacement at maximum load were increased by 15 percent, 16 percent and 100 percent, respectively, over those measured for the baseline joints. Also, joints made with laser-structured surfaces can absorb approximately 200 percent more energy than the conventionally prepared baseline joints, researchers reported.
Sabau noted that the process also doubles the energy absorption in the joints, which has implications for crash safety and potential use in armor for people and vehicles. Tim Skszek of Magna International (Troy, Michigan), a project partner, shares Sabau’s enthusiasm.
“The results are most encouraging, enabling the automated processing of a multi-material carbon fiber-aluminum joint,” Skszek said. “With this work, we were able to focus on addressing the gaps in technology and commercial use, and we look forward to applying these findings to products.”
Learn more: Laser treatment, bonding potential road to success for carbon fiber
The Latest on: Carbon fiber composites
[google_news title=”” keyword=”carbon fiber composites” num_posts=”10″ blurb_length=”0″ show_thumb=”left”]
via Google News
The Latest on: Carbon fiber composites
- Designing an infused, two-piece composite baseball baton April 26, 2024 at 11:20 pm
With its Icon BBCOR bat, Rawlings leveraged its experience in braided fabrics and RTM to create an optimized, higher-performance two-piece design.
- Landrum to see carbon fiber bike manufacturing near Saluda Grade Rail Trail, what to knowon April 26, 2024 at 7:14 pm
Another carbon fiber bicycle element manufacturer is headed for the Saluda Grade Rail Trail. During the Criterium bike race on Friday, April 26, Boyd Cycling announced they would bring Munich ...
- Local cycling companies acquire German carbon rim makeron April 26, 2024 at 4:00 pm
Two Upstate cycling manufacturers and a group of local investors have acquired a German carbon rim manufacturer and are moving production equipment to Spartanburg County. Greenville’s Boyd Cycling ...
- First Look at Boyd’s Woven Carbon Rimson April 24, 2024 at 1:10 pm
Boyd shows off a woven carbon fiber "sock" that'll become a high-end rim, and it's all going to be made in the USA.
- Aviation-specific battery system uses advanced composites to address electric, hybrid flighton April 23, 2024 at 10:23 pm
BOLDair’s composite enclosures, compression structures and thermal runaway management enables high-performance electric energy storage.
- China Composites Industry Report 2024: Glass, Carbon and Aramid Market Size, Trends and Growth Analysis, 2018-2023 and 2024-2030on April 23, 2024 at 7:20 am
The "Chinese Composites Market: Market Size, Trends and Growth Analysis" report has been added to ResearchAndMarkets.com's offering.Chinese composites market is expected to reach an estimated $20.8 ...
- Carbon Fiber Market Projected to Surpass USD 17.82 Billion by 2031, Driven by Surging Demand in Automotive and Aerospace Industrieson April 22, 2024 at 6:38 am
Carbon Fiber Market Projected to Surpass USD 1782 Billion by 2031 Driven by Surging Demand in Automotive and Aerospace Industries ...
- Munich Composites Bringing Woven Carbon Fiber Rim Production to USAon April 17, 2024 at 12:08 pm
North American brands now have a high-end woven carbon fiber RTM option for onshoring their rim manufacturing. The post Munich Composites Bringing Woven Carbon Fiber Rim Production to USA appeared ...
- 'Nano stitches' enable lighter and tougher composite materialson April 16, 2024 at 8:12 am
To save on fuel and reduce aircraft emissions, engineers are looking to build lighter, stronger airplanes out of advanced composites. These engineered materials are made from high-performance fibers ...
- Lightweighting the Future: Carbon Fiber Composites Market to Reach US$ 39 Billion by 2033on April 16, 2024 at 3:10 am
The global carbon fiber composites market is projected to reach US$ 39,412.1 million by 2033, capturing a significant CAGR of 6.5% during the forecast period. Continuous developments in advanced ...
via Bing News