Article, 2024

Ultra-tough architected adhesive joints for integrated composite processing and bonding

Composites Part A Applied Science and Manufacturing, ISSN 1878-5840, 1359-835X, Volume 177, Page 107949, 10.1016/j.compositesa.2023.107949

Contributors

van Innis, Charline (Corresponding author) [1] Budzik, Michal Kazimierz 0000-0002-6429-0364 [2] Pardoen, Thomas 0000-0003-0569-9466 [1] [3]

Affiliations

  1. [1] Université Catholique de Louvain
    2. [NORA names: Belgium; Europe, EU; OECD];
  2. [2] Aarhus University
    3. [NORA names: AU Aarhus University; University; Denmark; Europe, EU; Nordic; OECD];
  3. [3] Wel Research Institute, Avenue Pasteur, 6, 1300 Wavre, Belgique
    4. [NORA names: Belgium; Europe, EU; OECD]

Abstract

Deployment of advanced polymer-based composites in critical structures requires, among others, breakthroughs in adhesive bonding solutions. Indeed, available methods still suffer from limited fracture toughness of adhesives and from time-consuming bonding processes. Here, we demonstrate a novel concept of architected thermoplastic joints with exceptional fracture resistance up to 5000 J/m2, fully integrated with the composite resin transfer molding process, hence simultaneously targeting both limitations. This extreme toughness is activated through controlled 3D printed hollow pattern within a Nylon bondline. A synergetic combination of plastic dissipation, crack deflection, branching and arrest is tuned by changing the pattern characteristics. Three failure regimes are unraveled through fractographic analyses and finite element models. A stress-at-a-distance fracture criterion, identified for each constituent, quantitatively predicts the toughness variations along the crack path. This approach, amenable to dissimilar bonding between metals and composites, paves the road towards novel and higher performance structures and manufacturing approaches.

Keywords

adhesion, analysis, approach, arrest, bonding process, bonding solution, bonds, branches, breakthrough, characteristics, combination, composition, composition process, concept, controlling 3D, crack, crack deflection, crack path, criteria, critical structures, deflection, deployment, dissipation, element model, failure, failure regime, finite element model, fractographic analysis, fracture, fracture criterion, fracture resistance, fracture toughness, fracture toughness of adhesives, high-performance structures, hollow pattern, joints, limitations, manufacturing, manufacturing approach, metal, method, model, molding process, path, pattern characteristics, patterns, performance structures, plastic dissipation, polymer-based composites, process, regime, resin transfer molding process, resistance, road, solution, structure, synergetic combination, thermoplastic joints, toughness, toughness of adhesives, toughness variation, transfer molding process, variation

Funders

  • Fund for Scientific Research

Data Provider: Digital Science

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