Opmimization of hybrid composite-metal joints

icaf2023 Tracking Number 138

icaf2023 poster

Better understanding of the methods of composite and metal joints in airline industry has significant role in reducing the operational costs. New joining methods between composites and metals are investigated involving additively manufactured rivet pins. This paper focuses on numerical analyses of the strength of the joint, as well as optimization of the pins. The joint morphologies of metal to metal, metal to composite materials were studied through the finite element analysis, involving individual and multiple pins and adhesive-bonding layer joint models. The model divides into three parts, top metal plate with a pin growing on the bottom surface, middle adhesive layer and the bottom composite plate. The mesh of model is shown in Figure 1 and the parameters of the model are detailed in Table 1. By setting certain boundary conditions(fixed the left side of the metal plate) and loads(along the X direction on the right side of the composite plate), results show that the largest bending stress in the pin occurs at the cross section between the bottom of the pin and the metal plate. In addition, bearing stresses around the composite hole for the pin increases with the external tensile loading. Besides, a plot of the shear stress along the loading direction can be obtained by modeling six pins uniformly distributed along the center line of the adhesive layer in the X direction(Figure2). The conclusion is that by optimizing the shape of the pins, the shear stress and axial stress are reduced. A parametric study is carried out for joint design optimization involving aluminum and titanium alloys and carbon fibre reinforced composites. Following the optimization, experimental study using additive manufactured pins are to be conducted. This study put forward optimization of joining configurations between composites and metals for improved strengths.