Joining of C/SiC for aerospace applications

To join C/SiC to C/SiC with a new, pressure-less composite joining material and technique, for high performance application

An Epoxy Adhesive Crosslinked through Radical‐Induced Cationic Frontal Polymerization

AbstractUV‐initiated cationic frontal polymerization is exploited as a solvent‐free, extremely fast, and low‐temperature technique to obtain epoxy‐based adhesives. Epoxy formulations are prepared by blending commercial resins at different weight ratios and adding photo and thermal initiators at different percentages. In addition, the influence of other critical parameters, including the joint thickness, the nature of the adherends, and the temperature, is studied. As the reaction front is thermally sustained, the boundary conditions play a key role during the curing process and heat dissipation through the adherends in particular. The thermal properties of the epoxy formulation are studied through differential scanning calorimetry analysis, and the joint strengths are investigated by carrying out single lap off‐set shear tests under compression. The results demonstrate the feasibility of obtaining joints by means of the radical induced cationic frontal polymerization of the epoxy adhesives, which exhibit comparable epoxy group conversion and mechanical performances to the ones cured by traditional energy‐intensive techniques

Atmospheric pressure plasma jet for surface texturing of C/SiC

C/SiC composites are materials to be used in harsh environments overcoming the limits imposed by the intrinsic brittleness of their ceramic constituents while providing both high mechanical performances at high-temperature temperatures and low weight. In order to manufacture the final component, joining C/SiC, to itself or to other materials, is often necessary, and it is critical to maximize the strength of the joints (similar or dissimilar) in order to meet reliability criteria. In the present work, a pre-joining treatment based on an atmospheric pressure plasma jet (APPJ) was proposed to introduce a brush-like texture on the surface via the selective removal of carbon fibers. The investigation of treated surfaces via electron microscopy and confocal 3D-profilometry confirmed that the treatment was effective in introducing a brush-like texture and in increasing the available contact area. Wettability test and inspection of cross-section of CB4 wetted samples were then carried out. The latter confirmed the formation of anchoring points given by the brush-like texture. Finally, the effectiveness of the treatment in improving the joint strength was assessed by comparing the apparent shear strength of CB4 brazed composites, with and without the APPJ pre-treatment. The joints with plasma pre-treated C/SiC showed a shear strength of about 66 MPa, 44% more than the strength of joints produced with untreated C/SiC

Joining and Coating of Plasma Electrolytic Oxidated Aluminum Using a Silica Preceramic Polymer

This study evaluates the effectiveness of a silica preceramic polymer for joining and coating Plasma Electrolytic Oxidated (PEO) aluminum components at temperatures below 200 °C. PEO aluminum slabs were coated and joined with a silica precursor polymer (Durazane1800, Merck, Darmstadt, Germany), both with and without the addition of 48 wt% silica nanoparticles, and cured at 180 °C for 4 h in air. Thermogravimetric analysis assessed the curing process and thermal stability, while X-ray diffraction confirmed the polymer’s conversion to amorphous silica after heating at 1200 °C. Resistance to humid environments was tested by soaking coated samples in tap water for a week, with no mass variation observed. Mechanical testing through tensile mode and tensile lap tests showed that adding 48 wt% silica nanoparticles significantly improved joint cohesion and nearly quadrupled mechanical strength. Fracture surfaces were examined using Field Emission Scanning Electron Microscopy, and composition analysis was performed with Energy Dispersion X-ray Spectroscopy. Crack detection was conducted using Computer Tomography with an in situ bending test setup to obtain the mechanical resistance of the PEO coating. The results indicate that the silica preceramic polymer is suitable for joining and coating PEO aluminum components, with silica nanoparticles enhancing mechanical strength and providing excellent thermal stability and resistance to humidity

Effect of pulsed laser irradiation on the SiC surface

The effect of a pulsed laser irradiation (Nd:YVO4, 1064 nm) in air on the Surface morphology and chemical composition of silicon carbide and on the adhesion with an epoxy adhesive was investigated. Scanning and transmission electron microscopies, atomic force microscopy, and X-ray photoelectron spectroscopy revealed that the laser treatment reduced the contamination level of the Surface and induced the formation of a silica-based nanostructured colum nar layer on the SiC surface. The mechanism for the formation of five different microstructural regions is described in this paper. In addition, the formation of a 5-10-nm-thick graphite layer between the oxide layer and SiC was observed. The joining test with Hysol EA9321 showed that the nanostructured columnar silica layer was completely infiltrated by the adhesive, thus leading to a significant increase in the joined specific area and a mecha nical interlocking at the adhesive/substrate interface. Nevertheless, the apparent shear strength of the joined SiC samples slightly decreased after the laser processing of the surfaces from about 42 MPa for lapped SiC to about 35 MPa for laser-nanostructured SiC. The formation of the graphite layer was found to be responsible of the poor adhesion properties of the SiC surfaces modified by the laser radiation

SiC foam sandwich structures obtained by Mo-wrap joining

SiC foams sandwiched between two Ceramic Matrix Composite (CMC) skins are of interest for several high temperature applications ranging from aeronautics to energy production. In this paper, SiC foams were joined to C/SiC composites by the “Mo-wrap” method to obtain sandwich structures. The Mo-wrap method is a recently developed joining technique: it consists of wrapping Si foils inside a Mo wrap in order to prevent molten silicon leaking from the joined area and infiltrating SiC foam and C/SiC during the joining process. Compression and thermal shock resistance tests were performed on the C/SiC – SiC foam – C/SiC sandwich obtaining sound results

TEM and zeta potential titration as suitable techniques for investigating the joining of modified ceramic surfaces

Transmission Electron Microscopy (TEM-EDS) and Zeta potential titration of ceramic surfaces allowed researchers to go inside their adhesion mechanism when joined with an adhesive. The case study concerned the plasma Corona treatment to improve the joint strength between SiC surfaces joined with an epoxy adhesive. The formidable mechanical and chemical properties inherent to silicon carbide pose challenges in applying conventional methods like mechanical machining and wet etching for surface texturing. Exploring alternative strategies, plasma Corona treatment which is an Atmospheric Pressure Plasmas (APPs) process emerges as a potential solution. The mechanism of chemical interaction and mechanical interlocking between plasma-treated surfaces and the epoxy adhesive used for the joining was never explored in detail and proven. The presence of layers with different crystallographic natures and chemical compositions was assessed by TEM-EDS: an amorphous silica layer was produced by the corona activation treatment and it created a mechanical anchoring system when penetrated by the adhesive. The zeta potential titration as a function of pH evidenced that untreated SiC had a surface with amphoteric functional groups, while the Corona treatment induced the formation of surface functional groups (OH) with a strong acidic behavior on SiC. The investigated epoxy adhesive exposed a prevalence of basic amino groups. Zeta potential titration curves highlighted the chemical interaction between the treated SiC surfaces and the epoxy adhesive: the large electrostatic attraction between the OH groups of the treated SiC and the amino groups of the epoxy adhesive had a role in the mechanical strength of the joining. TEM and Zeta potential titration can be proposed as suitable techniques to evaluate the effectiveness of the plasma corona discharge system in modifying the surface of SiC and to solidify its standing in comparison to other established surface modification techniques to improve SiC-based joints

Torsion Test vs. Other Methods to Obtain the Shear Strength of Elastic-Plastic Adhesives

Nowadays adhesive joints are more and more used; therefore, a precise and reliable shear strength measurement of these joints is necessary to design and predict a final components’ performance. This work aimed to assess the shear strength value of adhesively joined ceramics (SiC, Si3N4) and steel in the case of an elasto‐plastic (ductile) joining material (Loctite EA 9321 AERO) by an experimental campaign and associated analytical modelling. The joined samples were tested using a single lap offset test in compression (SLO), an asymmetrical 4‐point bending test (A4PB, ASTM C1469), and by torsion on fully joined hourglass shaped samples (THG). A simple model based on the elastic‐plastic response in shear was proposed to fit the torque‐rotation curve measured in the torsion tests. The results showed that, with the adopted test methods and conditions, and by using the model, consistent values of shear strength could be obtained by torsion tests