FAST AND ROBUST JOINING PROCESS FOR AEROSPACE COMPONENTS BY LOCAL HEATING OF PASTE ADHESIVES

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1 DISS.-No. ETH FAST AND ROBUST JOINING PROCESS FOR AEROSPACE COMPONENTS BY LOCAL HEATING OF PASTE ADHESIVES A thesis submitted to attain the degree of DOCTOR OF SCIENCES OF ETH ZÜRICH (Dr. sc. ETH Zürich) presented by ALBERTO SÁNCHEZ CEBRIÁN Dipl. Industrial Engineer Universitat Politècnica de Catalunya (2009) born citizen of Spain accepted on the recommendation of Prof. Dr. Paolo Ermanni, examiner Dr. Markus Zogg, co-examiner Prof. Dr. Heinz Voggenreiter, co-examiner 2014

2 Summary (English) Since the 70s, industry is doing research in new adhesive systems for joining composites for structural applications. Adhesive bonding permits having lighter structures and thus more efficient solutions than today s aerospace state of the art, riveting. Additionally, the use of adhesives does not require drilling the components, which is especially beneficial for joining composite materials. Typically, the curing of paste adhesives is carried out in forced convection ovens, applying isothermal heating cycles recommended by the supplier. The variation of the curing temperature during the process is today not considered due to its high energy consumption. To avoid this limitation, the use of induction heating to heat locally the bondline is considered in this doctoral thesis. This technique allows heating the assembly faster and thus saving energy resources and time. In this context, the acceleration of the curing process of a paste adhesive by increasing the heating temperature during the process is investigated. However, the increment of the curing temperature leads to void formation and thus to the thermal degradation of the paste adhesive. This phenomenon is caused by the evaporation of moisture, the degradation of chemical components and the expansion of air trapped during the mixing process. The increment of void content affects the mechanical performance of the bonded system. To deal with this limitation, a novel modeling of the void formation during the curing process considering the degree of cure is developed in this doctoral thesis. The fundamental idea of this approach is that the evaporation of the paste adhesive that leads to void formation decreases iii

3 with curing progression. Therefore, a novel thermal degradation model for the evaporation of paste adhesives is defined as a function of temperature, time and the degree of cure. Once the mass evaporation is modeled, the relation between evaporated mass and void formation is experimentally established, completing the void prediction model for paste adhesives. This model is then used to find the optimal strategy to accelerate the curing process of paste adhesives without increasing the void formation. This approach is applied to two different paste adhesive systems in order to ensure the repeatability of the research findings. The results show a reduction of more than 85 % of the processing time compared to the reference curing cycle without affecting the mechanical performance of the joint. Finally, the methodology investigated is applied to a real aircraft component, defining the guidelines to ensure the robustness of the process under real component geometries. iv

4 Zussammenfassung (Deutsch) Seit den siebziger Jahren forscht die Industrie an neuen Klebstoffsystemen zur Verbindung von Faserverbunden für Strukturanwendungen. Kleben erlaubt leichtere Strukturen und damit effizientere Lösungen als der heutige Standard in der Luft- und Raumfahrt, das Nieten. Zudem erfordert die Verwendung von Klebstoff kein Bohren der Komponenten, was besonders vorteilhaft für das Fügen von Faserverbundwerkstoffen ist. Typischerweise wird das Aushärten von Pastenklebstoffen in Öfen mit erzwungener Konvektion durchgeführt, wobei vom Hersteller empfohlene Heizzyklen zur Anwendung kommen. Die Änderung der Aushärtetemperatur während des Prozesses wird heutzutage wegen ihres hohen Energieverbrauchs nicht berücksichtigt. Um diese Beschränkung zu überwinden, wird in dieser Doktorarbeit die Anwendung induktiven Heizens betrachtet, um die Klebenaht lokal zu erwärmen. Diese Technik erlaubt schnelleres Aufheizen und damit Ersparnisse an Ressourcen und Zeit. In diesem Kontext wird die Beschleunigung des Aushärteprozesses eines Pastenklebstoffs durch Erhöhung der Heiztemperaturen während des Prozesses untersucht. Die Steigerung der Aushärtetemperatur führt jedoch zu Porenbildung und damit zur thermischen Degradation des Klebers. Dieses Phänomen wird durch die Verdunstung von Feuchtigkeit, die Degradation chemischer Komponenten und die Ausdehnung während des Mischvorgangs eingeschlossener Luft verursacht. Die erhöhte Porenkonzentration beeinträchtigt die mechanischen Eigenschaften der Klebeverbindung. Um mit dieser Beschränkung umzugehen, wird in dieser Dissertation eine neuartige Modellierung der Porenbildung während des v

5 Aushärteprozesses unter Berücksichtigung des Aushärtegrades entwickelt. Die grundlegende Idee dieses Vorgehens setzt daran an, dass die zur Porenbildung führende Verdampfung des Klebstoffes mit fortschreitender Aushärtung abnimmt. Deshalb wird ein neuartiges Degradationsmodell für die Verdunstung von Pastenklebstoffen in Funktion von Temperatur, Zeit und Aushärtegrad formuliert. Im Anschluss an die Modellierung der Verdampfung wird eine Beziehung zwischen verdampfter Masse und Porenbildung experimentell hergestellt, welche das Modell vervollständigt. Dieses Modell wird anschliessend dazu verwendet, die optimale Strategie zur Beschleunigung des Aushärtevorgangs von Pastenklebstoffen ohne erhöhte Porenbildung zu finden. Dieser Ansatz wird auf zwei verschiedene Klebstoffsysteme angewandt, um die Wiederholbarkeit der Forschungserkenntnisse sicherzustellen. Die Ergebnisse zeigen eine Reduktion der Verarbeitungszeit um mehr als 85 % im Vergleich zum Referenzzyklus, ohne Beeinträchtigung der mechanischen Eigenschaften der Verbindung. Schliesslich wird die untersuchte Methodik auf eine reale Flugzeugkomponente angewandt, wobei Richtlinien aufgestellt werden, welche die Robustheit des Verfahrens bei realen Komponentengeometrien gewährleisten sollen. vi

6 Resumen (Español) Desde los años 70, la industria investiga nuevos sistemas de pastas adhesivas para unir estructuras de materiales compuestos. Su uso permite que las uniones sean más ligeras, consiguiendo así soluciones más eficientes que la técnica de referencia hoy en día en la industria aeroespacial, ribetes. Además el uso de adhesivos tiene la ventaja de que los componentes a unir no son agujereados, un hecho especialmente beneficioso en la unión de materiales compuestos. Normalmente, el proceso de curado de pastas adhesivas tiene lugar en hornos de convección forzada, mediante la aplicación de ciclos de calentamiento isotérmicos recomendados por el fabricante. Hoy en día, la variación de temperaturas durante el proceso no está considerada debido a su alto consumo energético. Para evitar esta limitación, en esta tesis doctoral se considera el uso de calentamiento por inducción. Esta técnica permite calentar la unión rápidamente con un bajo coste de energía. Bajo este concepto, esta tesis investiga la aceleración del proceso de curado de pastas adhesivas incrementando la temperatura durante el proceso. De todas maneras, el incremento de la temperatura de curado está limitado por la degradación térmica de la pasta adhesiva debido a la formación de poros cuando se aplican altas temperaturas. Dichos poros se forman debido a la evaporación de humedad, degradación de los componentes químicos y a la expansión del aire atrapado durante la mezcla del adhesivo. Esto provoca un descenso de las propiedades mecánicas de la unión. Para solucionar este problema, esta tesis desarrolla un nuevo modelo para formación de poros considerando el grado de curado durante el proceso de calentamiento. vii

7 La idea fundamental de este modelo es que la cantidad de degradación térmica producida por la evaporación de la pasta adhesiva disminuye durante proceso de curado. Por este motivo, esta tesis define un nuevo modelo de degradación en función de temperatura, tiempo y grado de curado. Una vez el nuevo modelo está definido, la relación entre masa evaporada y generación de poros se establece experimentalmente, completando así un modelo para la predicción de porosidad en pastas adhesivas. Dicho modelo se utiliza para definir la estrategia óptima de calentamiento de pastas adhesivas sin incrementar la porosidad. Esta técnica se aplica a dos pastas adhesivas diferentes para asegurar su respetabilidad. Los resultados muestran una reducción del 85 % del tiempo de curado respecto al ciclo de curado recomendado por el fabricante sin afectar las propiedades mecánicas de las uniones. Finalmente, la metodología investigada es aplicada a un componente real de un avión, definiendo las directrices para poder así asegurar la solidez del proceso para componentes reales. viii

8 Resum (Català) Des dels anys 70, la indústria fa recerca sobre nous sistemes de pastes adhesives per unir estructures fetes de materials composts. El seu ús permet que les unions siguin més lleugeres, aconseguint solucions més eficients que la tècnica de referència avui en dia a la indústria aeroespacial, els rivets. Amés, l ús d adhesius te l avantatge de que els components a unir no son foradats, un fet especialment beneficiós en la unió de materials compostos. Normalment, el procés de curat de pastes adhesives té lloc a horns de convecció forçada, mitjançant l aplicació de cicles d escalfament isotèrmics recomanats pel fabricant. Avui en dia, la variació de les temperatures durant el procés no està considerada degut a l elevat consum energètic. Per evitar aquesta limitació, en aquesta tesis doctoral es considera l ús de l escalfament per inducció. Aquesta tècnica permet escalfar la unió ràpid, estalviant temps i energia. Sota aquest concepte, aquesta tesis fa recerca sobre l acceleració del procés de curat de pastes adhesives incrementant la temperatura del procés. Aquest increment, però, està limitat per la degradació tèrmica de la pasta adhesiva degut a la formació de porositat quan s apliquen altes temperatures. Aquests, es formen degut a l evaporació d humitat, degradació del components químics i a l expansió de l aire atrapat durant la barreja de l adhesiu. L increment de porositat provoca una caiguda de les propietats mecàniques de la unió. Per a solucionar-ho, aquesta tesis desenvolupa un nou model per a la formació de porositat considerant el grau de curat durant el procés d escalfament. La idea principal d aquest model és la quantitat de degradació tèrmica produïda per l evaporació de la pasta adhesiva dismi- ix

9 nueix durant el procés de curat. Per aquesta raó, aquesta tesis defineix un nou model de degradació en funció de la temperatura, el temps i el grau de curat. Un cop el nou model està definit, s estableix experimentalment la relació entre la massa evaporada i la formació de porositat, completant un model per a la predicció de porositat de les pastes adhesives. Aquesta model s empra per a recercar l estratègia òptima d escalfament de pastes adhesives sense incrementar la seva porositat. Aquesta tècnica s aplica a dos sistemes adhesius diferent per a poder assegurar la seva repetibilitat. Els resultats mostren una reducció de més del 85 % del temps de curat comparat amb el cicle de referència recomanat pel fabricant sense afectar les propietat mecàniques de les unions. Finalment, la metodologia recercada s aplica a un component real d un avió, definint les directrius per a poder assegurar així la solidesa del procés en components reals. x

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