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Analysis of Metal to Composite Adhesive Joins in Space Applications
Linköping University, Department of Management and Engineering, Mechanics .
2010 (English)Independent thesis Advanced level (professional degree), 20 credits / 30 HE creditsStudent thesisAlternative title
Analys av limförband mellan metall och kompositmaterial i rymdtillämpningar (Swedish)
Abstract [en]

Within the European space programme, a new upper stage engine (Vinci) for the Ariane 5 launcher is being developed, and the Volvo Aero Corporation (VAC) is contributing with tur-bines for the fuel turbopumps. This MSc thesis investigates the possibility of designing the Turbine Exhaust Duct (TED) of the Vinci-engine in a carbon fibre composite material with adhesively attached titanium flanges. The focus of the project has been on stress analyses of the adhesive joints using Finite Element Methods (FEM), more specifically by using a cohe-sive zone material (CZM) to model the adhesive layer. Analysing adhesive joints is complex and an important part of the work has been to develop and concretise analysis methods for future use within VAC.

To obtain the specialised material parameters needed for a CZM analysis, FE-models of ten-sile test specimens were analysed and the results compared to those of equivalent experimen-tal tensile tests. These parameters were then used when analysing the TED geometry with load cases specified to simulate the actual operation conditions of the Vinci engine. Both two-dimensional axisymmetric and fully three-dimensional models were analysed and, addition-ally, a study was performed to evaluate the effect of cryogenic temperatures on the strength of the joint.

The results show that the applied thermal and structural loading causes local stress concentra-tions on the adhesive surface, but the stresses are not high enough to cause damage to the joint if a suitable joint design is used. Cryogenic temperatures (-150 °C) caused a significant strength reduction in the tensile specimens, partially through altered adhesive properties, but no such severe effects were seen in the temperature-dependent FE-analyses of the TED. It should be pointed out however, that some uncertainties about the material parameters exist, since these were obtained in a rather unconventional way. There are also several other impor-tant questions, beside the strength of the adhesive joint, that need to be answered before a metal-composite TED can be realised.

Abstract [sv]

Volvo Aero deltar i utvecklingen av Vinci, en ny motor till det övre steget i den europeiska Ariane 5-raketen. Detta examensarbete behandlar möjligheten att tillverka ett turbinutlopp (TED) till vätgasturbinen i Vinci-motorn i kompositmaterial med flänsar i titan för att på så sätt uppnå en viktbesparing gentemot den tidigare konstruktionen i gjuten Inconel 718. Fokus har legat på att analysera hållfastheten i de limfogar som är tänkta att sammanfoga huvudröret med flänsarna, genom analyser med finita elementmetoden (FEM). Ett viktigt syfte har även varit att, för Volvo Aeros räkning, samla praktiska erfarenheter angående numerisk analys av limfogar, särskilt med användning av kohesiva zon-element för att modellera limfogen.

FEM-analyser har gjorts av provstavsmodeller, där resultaten sedan jämförts med experimen-tella dragprovsresultat för att ta fram lämpliga material- och modelleringsparametrar för ana-lys med kohesiva zonelement. Därefter tillämpades dessa parametrar i analyser av den verkli-ga TED-geometrin med relevanta lastfall framtagna för att simulera driftsförhållandena i Vin-ci-motorn. Lastfallsanalyser med både tvådimensionellt axisymmetriska och tredimensionella geometrimodeller genomfördes, liksom uppskattningar av limfogens styrka vid kryogena driftstemperaturer.

Resultaten pekar entydigt mot att en limfog med en ändamålsenlig tvärsnittsgeometri skulle hålla för de angivna lasterna utan att ta skada. De spänningskoncentrationer som uppstår ger lokalt höga spänningar i limmet, men inte på nivåer som skulle kunna orsaka brott. Det finns dock en viss osäkerhet angående riktigheten i materialparametrarna då en något okonventio-nell metod användes för att ta fram dessa. Flera stora frågor finns fortfarande kvar att besvara innan en metall-komposit konstruktion kan realiseras, inte minst hur flödeskammarens kom-plicerade geometri skall kunna tillverkas i kompositmaterial.

Place, publisher, year, edition, pages
2010. , 103 p.
Keyword [en]
cohesive zone model, adhesives, composites, cryogenic
National Category
Mechanical Engineering
Identifiers
URN: urn:nbn:se:liu:diva-57228ISRN: LIU-IEI-TEK-A—10/00812—SEOAI: oai:DiVA.org:liu-57228DiVA: diva2:324054
Presentation
2010-06-04, A36, Linköpings Universitet, 581 83 LINKÖPING, 11:25 (Swedish)
Uppsok
Technology
Supervisors
Examiners
Available from: 2010-10-05 Created: 2010-06-14 Last updated: 2010-10-05Bibliographically approved

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