In pursuit of tough and damage tolerant adhesive bonded lightweight structures using material architecture

减少温室气体排放的全球趋势点燃了人们对轻量化材料的兴趣，轻量化材料有望在汽车行业实现显著的市场增长。在包括铝合金和纤维增强聚合物在内的材料组合不断增加的推动下，寻找适合多材料结构的连接技术成为人们关注的焦点。最近的发展表明，粘合剂粘合可以取代传统的紧固方法，并可以大大减少装配时间和成本。然而，由于制造和服务缺陷可能导致灾难性的故障，因此对这种连接技术仍然缺乏信心。由于增材制造和脉冲激光表面制备领域的最新发展，申请人正在开发各种方法来阻止裂纹扩展并防止灾难性故障。所提出的方法针对关节的关键属性，即配合层的几何形状（衬底结构），结合线的组成（结合线结构）和界面粘附景观（界面结构）。申请人研究的下一阶段，即提出的发现项目的重点，将过渡到上述方法的一致整合。长期目标是开发一种全新的整体制造方法，并能够极大地增强韧性和损伤容限。为了实现这一目标，“发现”项目将追求以下相关的短期目标：1)开发和优化用于轻质金属和复合材料粘合的激光预处理；2)研究可扩展的方法来制造具有结构结合线的耐损伤粘合接头；3)了解结构基板在多材料粘接接头脱粘力学中的作用。这项研究将使用滑铁卢大学广泛的材料加工和表征实验设施，包括一个新的cfi资助的多波长激光平台，用于金属和聚合物的表面制备。最先进的实验与先进的模型相结合，将为未来的轻量化和耐损伤结构铺平道路，从而降低燃料消耗和排放。加拿大的利益是通过直接技术转让给关键的终端接受者，如汽车和航空航天公司（如麦格纳、丰田、庞巴迪）而获得的。七名研究生将在整个项目中接受培训。这些研究人员将接受汽车和航空航天工业所需的高度理想技能的培训，例如粘合剂粘合，机械表征，表面/界面分析，数值技术以及应用于损伤和断裂的计算力学。他们在加拿大工业界和学术界招募这些熟练的专业人员将进一步支持加拿大未来的竞争力。

Global trends to reduce greenhouse emissions have ignited the interest for lightweight materials which are poised for significant market growth in the automotive industries. Fuelled by the increasing material mix, that includes aluminum alloys and fiber-reinforced polymers, the search for joining technologies suitable for multi-material structures is under the spotlight. Recent developments suggest that adhesive bonding can replace traditional fastening methods and could dramatically decrease assembly time and costs. However, because manufacturing and service defects can lead to catastrophic failures, there is still a lack of confidence in this joining technology. Enabled by recent developments in the area of additive manufacturing and in surface preparation using pulsed lasers, various approaches are being developed by the applicant to hamper crack propagation and prevent catastrophic failures. The proposed methodologies targeted the joints' key attributes, i.e., the geometry of the mating layers (substrate architecture), the composition of the bondline (bondline architecture), and interfacial adhesion landscape (interface architecture). The next phase of the applicant's research, which is the focus of the proposed Discovery program, will transition toward a consistent integration of the above methodologies. The long-term goal is to develop a novel holistic manufacturing approach and enable extreme enhancement of toughness and damage tolerance. To achieve this goal, the Discovery program will pursue the following interrelated short-term objectives: 1) Develop and optimize laser pre-treatments for adhesive bonding of lightweight metals and composites; 2) Investigate scalable methods for manufacturing damage-tolerant adhesive joints with architected bondline; 3) Understand the role of architected substrates on the mechanics of debonding in multi-material adhesive joints. This research will use the extensive experimental facilities for material processing and characterization at Waterloo, including a newly CFI-funded multi-wavelength laser platform for surface preparation of metals and polymers. State-of-the-art experiments, paired with advanced modeling, will pave the way to future lightweight and damage-tolerant structures that will decrease fuel consumption and emissions. Canada's benefit is derived through the direct technology transfer to key end receptors, such as automotive and aerospace companies (e.g., Magna, Toyota, Bombardier). Seven graduate students will be trained throughout this program. These researchers will be trained in highly desirable skill sets needed in automotive and aerospace industries, such as adhesive bonding, mechanical characterization, surface/interface analysis, numerical techniques, and computational mechanics applied to damage and fracture. Their recruitment of these skilled professionals within the Canadian industry and academia will further support Canada's future competitiveness.