Atmospheric pressure plasma jet deposition of Si-based coupling films as surface preparation for structural adhesive bonding inthe aircraft industry: Comparison of joint durability after APPJ-CVD and solution derived silane treatments

Damages of metallic aircraft structures that occur during manufacturing, assembly and in service require local repair. Especially with current service-life extensions of ageing aircraft fleets, the importance of such repair methods is increasing. Typically, the repair of smaller damages on aluminium fuselage or wing skins is done by riveting a patch onto the flawed structure. However, the use of rivets reduces the strength of the structure and promotes fatigue. Joining the patch by adhesive bonding would not only offer more homogenous load distribution and weight savings, but even an increase of structural integrity. Metal adhesive bonding is commonly used in aeronautics, but requires elaborated surface treatments of the adherends, employing hazardous chemicals like chromates, due to the high durability demands. Furthermore, these treatments are usually tank processes that are not suitable for local repairs. Hence, there is a strong need for locally applicable surface preparation methods that allow safe and reliable adhesive bonding of primary aircraft structures. The aim of this thesis is to assess the – still emerging – method of atmospheric pressure plasma deposition of silicon (Si) containing compounds concerning its suitability as surface preparation for adhesive bonding of aluminium aerostructures. Atmospheric plasma deposition is not yet used in the aircraft industry, and the knowledge on functionality of this technology concerning bonding of aluminium parts is limited. Moreover, the durability requirements of the aircraft industry greatly exceed the standards in other industries. Hence, special attention is paid to a thorough analysis of the key characteristics of the deposited coupling films and their effectiveness in terms of adhesion promotion as well as joint durability under particularly hostile conditions. In order to do so, the altering mechanisms of the treated joints and the behaviour of the coupling films during accelerated ageing will be investigated in detail for the first time in this thesis. Furthermore, the influence of the aluminium surface pre-treatment (i.e. topography and oxide properties of the substrate) on the overall joint performance after coupling film deposition is thoroughly examined. Based on these findings, the surface preparation is optimised, and a process is developed to achieve maximal joint performance. As alternative local surface treatments prior to adhesive bonding, solution derived deposition of silane and sol-gel films have already been widely investigated and can be considered as reference, even though these techniques are rarely used in civil aeronautics. The knowledge on their effectiveness and capabilities in corrosive atmosphere is still very limited. Therefore, all analyses of degradation mechanisms are conducted for both plasma deposition and wet-chemical reference treatments to reveal the differences and communalities of the two Si-based coupling films. Physical and chemical analysis of the films, the oxides and the interfaces reveal differing, but interdependent failure mechanisms that are inhibited differently by the individual coupling films. Using the optimum deposition parameters, plasma films of only several nanometres in thickness significantly enlarge the corrosion resistance of bonded joints, reaching almost the level of anodising treatments with several micrometres thick oxides and strongly outperforming solution derived silane treatments. However, plasma film performance is found to be largely dependent on the precursor selection. With plasma deposition of 3-glycidoxypropyltrimethoxysilane, which has not been reported before, highest joint stability is achieved. Moreover, it is discovered that the properties of plasma and solution derived silane based films are complementary. It is shown that an optimised combined plasma and wet-chemical treatment process provides even superior resistance to bondline corrosion than state-of-the-art anodising techniques

Moisture Degradation of CTD-403: Testing the Application of Cyanate Ester Insulations to Fusion Devices

The fusion devices currently being developed present several challenges for magnet designers. One challenge lies within the electrical insulation, which must be able to withstand extreme temperatures (both cryogenic and elevated temperatures), large shear and compressive stresses, high operating voltages, and high levels of incident radiation. To address the need for better performing insulation systems, Composite Technology Development, Inc. (CTD) has developed CTD-403, a cyanate ester resin with increased radiation resistance, ease of processing and fabrication, low moisture absorption characteristics, and high mechanical and electrical strength at cryogenic and elevated temperatures. In this thesis, CTD-403 resin based insulation systems were tested under the operation guidelines of the Quasi-Poloidal Stellarator (QPS). Because the coils of QPS are water cooled, it is important to understand the effects of long term humidity exposure on the insulation. The effects of humidity on moisture absorption characteristics, dimensional stability, mechanical and electrical properties were characterized. Increasing the humidity level caused a corresponding increase in the saturation level, while increasing the temperature of exposure magnified these effects causing more pronounced non-Fickian behavior. The mechanical properties degraded with an increase in humidity level. Elevated temperature effects are more pronounced on the compressive properties than the tensile properties. The glass transition temperature was more greatly affected by elevated temperature exposure as opposed to increased humidity exposure, decreasing in both instances. The dielectric strength decreases with increased humidity level and exposure time. Based on these findings, the performance of cyanate ester resin based insulation systems is shown superior to that of traditional epoxy based resin systems in all performance measures. The degradation of the mechanical and electrical properties of the insulation from long term effects of humidity and elevated temperature exposure are shown to be within the performance criteria bounds, and the insulation is therefore recommended for use in current and future fusion programs

Atmospheric corrosion of painted galvanized and 55% Al-Zn steel sheets: results of 12 years of exposure

Zinc or 55%Al-Zn alloy-coated steel sheets, either bare or covered by different painting systems, have been exposed for 12 years to the action of the urban atmosphere at the CIDEPINT station located in La Plata (34° 50′ South, 57° 53′, West), province of Buenos Aires, Argentina. The samples exposed surface was evaluated through periodical visual inspections, standardized adhesion tests, and electrochemical impedance measurements. The ambient variables monitored were average annual rains and temperatures, time of wetness, sulphur and chloride concentration, relative humidity, and speed and direction of the winds. It was found that in this atmosphere, the corrosion resistance of the bare 55% Al-Zn/steel sheets was higher than of the galvanized steel, and the polyurethane painting system was more protective than the alkyd and epoxy ones, which degraded after 6-7 years of exposure.Facultad de Ingeniería (FI

Corrosion Science and Engineering

This presentation provides an overview of corrosion and corrosion prevention method

Review of world experience and properties of materials for encapsulation of terrestrial photovoltaic arrays

Published and unpublished information relating to encapsulation systems and materials properties was collected by searching the literature and appropriate data bases (over 1,300 documents were selected and reviewed) and by personal contacts including site and company visits. A data tabulation summarizing world experience with terrestrial photovoltaic arrays (50 installations) is presented in the report. Based on criteria of properties, processability, availability, and cost, candidate materials were identified which have potential for use in encapsulation systems for arrays with a lifetime of over 20 years high reliability, an efficiency greater than 10 percent, a total price less than $500/kW, and a production capacity of 500,000 kW/yr. The recommended materials (all commercially available) include, depending upon the device design, various borosilicate and soda-lime glasses and numerous polymerics suitable for specific encapsulation system functions

Sterilizable Liquid Propulsion System, Part 1 Final Report, 5 Oct. 1966 - 31 Mar. 1968

Exposure of assembled and fueled bipropellant liquid propulsion system to ethylene oxid

Assessment of microelectronics packaging for high temperature, high reliability applications

This report details characterization and development activities in electronic packaging for high temperature applications. This project was conducted through a Department of Energy sponsored Cooperative Research and Development Agreement between Sandia National Laboratories and General Motors. Even though the target application of this collaborative effort is an automotive electronic throttle control system which would be located in the engine compartment, results of this work are directly applicable to Sandia`s national security mission. The component count associated with the throttle control dictates the use of high density packaging not offered by conventional surface mount. An enabling packaging technology was selected and thermal models defined which characterized the thermal and mechanical response of the throttle control module. These models were used to optimize thick film multichip module design, characterize the thermal signatures of the electronic components inside the module, and to determine the temperature field and resulting thermal stresses under conditions that may be encountered during the operational life of the throttle control module. Because the need to use unpackaged devices limits the level of testing that can be performed either at the wafer level or as individual dice, an approach to assure a high level of reliability of the unpackaged components was formulated. Component assembly and interconnect technologies were also evaluated and characterized for high temperature applications. Electrical, mechanical and chemical characterizations of enabling die and component attach technologies were performed. Additionally, studies were conducted to assess the performance and reliability of gold and aluminum wire bonding to thick film conductor inks. Kinetic models were developed and validated to estimate wire bond reliability

Atmospheric corrosion of painted galvanized and 55% Al-Zn steel sheets: results of 12 years of exposure

Zinc or 55%Al-Zn alloy-coated steel sheets, either bare or covered by different painting systems, have been exposed for 12 years to the action of the urban atmosphere at the CIDEPINT station located in La Plata (34° 50′ South, 57° 53′, West), province of Buenos Aires, Argentina. The samples exposed surface was evaluated through periodical visual inspections, standardized adhesion tests, and electrochemical impedance measurements. The ambient variables monitored were average annual rains and temperatures, time of wetness, sulphur and chloride concentration, relative humidity, and speed and direction of the winds. It was found that in this atmosphere, the corrosion resistance of the bare 55% Al-Zn/steel sheets was higher than of the galvanized steel, and the polyurethane painting system was more protective than the alkyd and epoxy ones, which degraded after 6-7 years of exposure.Facultad de Ingeniería (FI