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ADMACOM - Advanced manufacturing routes for metal/composite components for
aerospace
M. Salvo* and ADMACOM TEAM
*Department of Applied Science and Engineering,
POLITECNICO DI TORINO, ITALY
www.admacomproject.eu
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
M. Ferraris (coordinator), M. Salvo, V. Casalegno – Politecnico di Torino (Italy)
K. Handrick - MT Aerospace AG (Germany)
C. Wilhelmi, M. Funke - Airbus Group Innovations (Germany)
T. Weissgaerber, T. Schubert, P. Imgrund, J. Weise, A. Schmidt - FraunhoferIFAM (Germany)
J. Kübler, J. Janczak-Rusch, G. Blugan, G. Mata Osoro, M. Chiodi - EMPA Swiss Federal Laboratories for Materials Science and Technology (Switzerland)
M.L. Muolo; A. Passerone, F. Valenza, S. Gambaro- Consiglio Nazionale delle Ricerche IENI (Italy)
M. J. Reece, P. Tatarko - Nanoforce Technology Limited (UK)
Admacom team
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
ADMACOM project at a glance
Objectives
Components & Methodology
Design of joined components
Novel joining materials and techniques High T brazing
Ultrasonic soldering
Max phases
Joining by SPS
Presurreless joining by glass-ceramics
Mechanical tests
Conclusions
Outline
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
ADMACOM is a “Factory of the Future” project launched in October 2013 to develop innovative manufacturing technologies based on advanced design of interfaces and of joining materials for aerospace components.
ADMACOM project
Copyright ESA/J.Huart
Intermediate eXperimental Vehicle (IXV)
KazEOSat-1 (c) Airbus Defence and Space
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
CMCs and ceramics - ultra-light-weight materials that can
support the extreme environments found in …
… the high-pressure turbine
CMC turbine blade, Ceralink Inc, www. ceralink.com
… the reentry vehicle
CMC body flap – MT Aerospace
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
CMCs and ceramics - ultra-light-weight materials that can
support the extreme environments found in …
… the satellite thruster
CMC combustion chamber element-Airbus group
SiC primary mirror. ASTRO-F Satellite www.ir.isas.jaxa.jp/AKARI/Outreach/
… the satellite structure and instruments
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
CMCs and ceramics - ultra-light-weight materials that can
support the extreme environments found in …
… the pump for power & desalination Industry
Keraman® Shaft Sleeves/Journal Sliding Bearingsfor Large Pumps in Power & Desalination Industry-MTAerospace
… the nuclear reactor
Control rod sleeves;fuel cladding tubes in light water reactors to replace Zr alloys.
Courtesy of Robert J. ShinavskiHyper-Therm HTC, Inc. USA, now Rolls-Royce
SiC-based full-ceramic cladding
Monolithic SiC end cap
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
CMCs and ceramics - ultra-light-weight materials that can
support the extreme environments found in …
… the automotive wear resistant components
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
CMCs and ceramics - ultra-light-weight materials that can
support the extreme environments found in …
… the automotive wear resistant components
CMCs and ceramics could be used right now to replace existing components with novel components with improved properties such as
light weight for reducing fuel consumption and CO2 emission. But …
their use is limited to very few applications because of the problem of joining them reliably
ADMACOM aims to develop new manufacturing routes for these components for aerospace looking at a wider market!
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
Components & methodology
Re-entry vehicle – joining of
• C/SiC to C/SiC or Ti alloy
• SiC/SiC to SiC/SiC or Ti alloy
ESA’s IXV reentry vehicle www.esa.int
C/SiC with C/SiC pins fixed together and C/SiC with Ti alloy (MT Aerospace)
Rod tube actuator
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
Components & methodology
Satellite – joining of
• SiC to SiC or Invar and Ti alloy
Silicon carbide space structures and instruments (AIRBUS group)
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
Components & methodology
Satellite – joining of
• SiC to SiC or Invar and Ti alloy
Silicon carbide space structures and instruments (AIRBUS group)
Joined components
Demo
Design and modelling
of joined components
Surface engineering
Novel joining
materials and
techniques
Characterisation
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
Joining without additional screws, the reduction of weight and number of parts, the higher flexibility in joining complex parts
Design of joined components
(1) Simple butt-joint configuration,
(2) Mortise and Tenon joint configuration
(3) Half-lap joint
M. Salvo et al. Int J Appl Ceram Tech (2012) 9 [4] 778-785.
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
Joining without additional screws, the reduction of weight and number of parts, the higher flexibility in joining complex parts
Design of joined components
(1) Simple butt-joint configuration,
(2) Mortise and Tenon joint configuration
(3) Half-lap joint
Joint type
(top view)
Average flexural
strength (MPa)
1
2
3
43±15
218±17
247±1
Mechanical machining (“joint type 2 and 3”) increases the flexural strength of a simple butt joint (joint type 1) by a factor of 6. the joining material is a commercial adhesive modified by adding 40 wt% SiCparticles.
M. Salvo et al. Int J Appl Ceram Tech (2012) 9 [4] 778-785.
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
Selective matrix or fibre removal from the composite surface and laser structuring of substrate surfaces.
Design of joined components
MetalJo
inin
gm
ater
ial
Metal
Join
ing
mat
eria
l
Metal
Metal
Courtesy of W-J Kim, KAERI, South Korea
Courtesy of W-J Kim, KAERI, South Korea
As-received Selective removal of SiC fibresfrom the SiC/SiC composite surface at POLITO
1450°c 4hs1450°c 2hs
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
Selective matrix or fibre removal from the composite surface and laser structuring of substrate surfaces.
Design of joined components
MetalJo
inin
gm
ater
ial
Metal
Join
ing
mat
eria
l
Metal
Metal
Courtesy of W-J Kim, KAERI, South Korea
Courtesy of W-J Kim, KAERI, South Korea
As-received Selective removal of SiC fibresfrom the SiC/SiC composite surface at POLITO
1450°c 4hs1450°c 2hs
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
Laser structuring of substrate surfaces.
Design of joined components
Figure 5 SEM images of BOOSTEC SiC 100 material (quality “as sintered”) before (left) and after (right) laser based surface structuring
Laser structuringof SiC surface atAIRBUS. Adhesivebonding and soldering
SiC surface before and after laser structuring
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
New high temperature brazing alloys
Ta based alloys, Co-Nb and Mo-Si alloys
Melting T up to 1655°C
Novel joining materials and techniques
Ta-Co_1 Ta-Co_2
Ta (at.%) Ni (at.%)
Ta (wt.%)
Ni (wt.%) TL (°C)
Ta-Ni_1 14.00 86.00 33.42 66.58 1366
Ta-Ni_2 38.00 62.00 65.39 34.61 1395Ta (at.%)
Co (at.%)
Ta (wt.%)
Co (wt.%) TL (°C)
Ta-Co_1 12.00 88.00 29.51 70.49 1290Ta-Co_2 50.00 50.00 75.43 24.57 1655
Phase diagram Ta-Co [acc. Kaufman, 1991]. IFAM, CNR-IENI
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
Ultrasonic soldering of laser structured SiC
Active solders, lead-free (Sn-Ti-Ag based alloys):
Joining at low temperatures (230-260°C), no flux, join in air, no pre-metallization of the substrate material.
Melting of the solder formation of oxides on the molten surface. The oxide layer needs to be disrupted by a mechanical activation via simple scouring the molten solder or by ultrasonic agitation
Novel joining materials and techniques
IFAM
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
Max phases
Joining with Ti3SiC2 (synthesised by microwave heating ≤ 2vol.% TiC and Ti3Si2) using Spark Plasma Sintering at controlled temperature and pressure in order to avoid a decomposition of Ti3SiC2.
Novel joining materials and techniques
Ti3SiC2
1350°C/55MPa/5min
NANOFORCE
SiCSiC
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
Max phases
Joining with Ti3SiC2 (synthesised by microwave heating ≤ 2vol.% TiC and Ti3Si2) using Spark Plasma Sintering at controlled temperature and pressure in order to avoid a decomposition of Ti3SiC2.
Novel joining materials and techniques
Ti3SiC2
1350°C/55MPa/5min
NANOFORCE
SiCSiC
Al2O3
SiC
Ti3SiC2
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
CVD SiC
Joining by Spark Plasma Sintering (SPS): 1600-1900 °C, about 60 MPa, 3-10 minutes
S. Rizzo et al., J Eur Ceram Soc (2014) 34 [4] 903-913
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
CVD SiC
Joining by Spark Plasma Sintering (SPS): 1600-1900 °C, about 60 MPa, 3-10 minutes
C/SiC
C/SiC
CVD-SiC
CVD-SiC
Ti based joint
Titanium – 130 µm
S. Rizzo et al., J Eur Ceram Soc (2014) 34 [4] 903-913
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
CVD SiC
Joining by Spark Plasma Sintering (SPS): 1600-1900 °C, about 60 MPa, 3-10 minutes
C/SiC
C/SiC
CVD-SiC
CVD-SiC
Ti based joint
Titanium – 130 µm
Titanium – 30 µm
Apparent shear strength of 17.3 ± 7.8 MPa.
S. Rizzo et al., J Eur Ceram Soc (2014) 34 [4] 903-913
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
NEW WETTING TEST at Nanoforce, UK, by using Spark Plasma Sintering (SPS). In-situ measurement of the contact angle using Spark Plasma Sintering (SPS) up to 2000-2300°C and heating rate is up to 1000°C/min.
Novel joining materials and techniques
Before melting 1550°C - 500°C/min 1600°C - 100°C/min 1600°C - 500°C/min
Ti6Al4V on CVD-SiC
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
Pressure-less joining by glass-ceramicsWhy glass-ceramics?
DTA(m
V/m
g)
CaO-Al2O3 (CA) as casted
Cons:
Creep T>Tg
Thermodynamic stability Pros
Tailored composition and thermo-mechanical properties
Pressure-less joining process
Crystallization > creep resistance
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
Pressureless joining by glass-ceramics
1
SiC
SiC
CA glass-ceramic
SiC
3CaO∙Al2O3, 3CaO∙SiO2
12CaO∙7Al2O3
A. Czyrska-Filemonowicz, AGH-PL
No amorphous phase detected after the joiningprocess. T melting about 1400°C
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
Pressureless joining of SiC by glass-ceramics
Shear test: torsion of hour-glass shaped CA joined SiC
103±12 MPaSiC
SiC
CA glass-ceramic
Ferraris et. al Int. J. Appl. Ceram. Technol., 1–7 (2014) DOI:10.1111/ijac.12248
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
Cyclic fatigue testing monolithic and joined test specimens (up to 1 Million Cycles in 28 hours) at EMPA
Mechanical tests
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
How to measure the shear strength of joined ceramics and CMC ?
1
Chunghao Shih et al. ICACC14
X
ZY
Comparison of shear strength tests
A4PBAsymmetrical four-point bending test (ASTM C1469)
TC
Torsion cylinderTT
Torsion Tube TS
Torsion square
THG
Torsion hour-glass
DNDouble notchedASTM C1292-00 & C1425-99
SLOsingle lap off set ASTM D905-03
DLODouble-lap offset
SLSingle lap offset
BTBrazilian testASTM B 898
X
ZY
Comparison of shear strength tests
A4PBAsymmetrical four-point bending test (ASTM C1469)
TC
Torsion cylinderTT
Torsion Tube TS
Torsion square
THG
Torsion hour-glass
DNDouble notchedASTM C1292-00 & C1425-99
SLOsingle lap off set ASTM D905-03
DLODouble-lap offset
SLSingle lap offset
BTBrazilian testASTM B 898
Politecnico di Torino
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
Conclusions
Advanced surface engineering is used to maximise interface strength for the joints by modelling and design of interfaces, advanced wettability studies, modification of surfaces, thermodynamic prediction and computer simulations of interface reactions.
In order to develop innovative manufacturing approaches, novel joining technologies and joining materials are/will be developed in ADMACOM such as: laser and mechanical structuring of surfaces to be joined, selective matrix removal from composite surface to obtain “brush-like” joints; novel and/or modified commercial brazes are/will be developed within ADMACOM.
ADMACOM is expected to significantly increase the potential application fields of the developed manufacturing approach for the benefit of the European aerospace industry and beyond.
M. Salvo - ECCM16, 24 June 2014, Seville, Spain
The research leading to these results has received funding from the European Community's 7th Framework Programme FP7 2007-2013 under the grant agreement n. 609188.
www.admacomproject.eu
Acknowledgements
Thank you for your attention
milena.salvo@polito.it
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