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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


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


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


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




… 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




… 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




… the automotive wear resistant components




… 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!


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



Satellite – joining of

• SiC to SiC or Invar and Ti alloy

Silicon carbide space structures and instruments (AIRBUS group)



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


Joining without additional screws, the reduction of weight and number of parts, the higher flexibility in joining complex parts


(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.


Joining without additional screws, the reduction of weight and number of parts, the higher flexibility in joining complex parts


(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.


Selective matrix or fibre removal from the composite surface and laser structuring of substrate surfaces.


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


Laser structuring of substrate surfaces.


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


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


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


IFAM


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.


Ti3SiC2

1350°C/55MPa/5min

NANOFORCE

SiCSiC


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.


Ti3SiC2

1350°C/55MPa/5min

NANOFORCE

SiCSiC

Al2O3

SiC

Ti3SiC2


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


CVD SiC


C/SiC

C/SiC

CVD-SiC

CVD-SiC

Ti based joint

Titanium – 130 µm



CVD SiC


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.



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.


Before melting 1550°C - 500°C/min 1600°C - 100°C/min 1600°C - 500°C/min

Ti6Al4V on CVD-SiC


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


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


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


Cyclic fatigue testing monolithic and joined test specimens (up to 1 Million Cycles in 28 hours) at EMPA

Mechanical tests


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


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.


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

[email protected]

http://www.admacomproject.eu/

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