CAREER: In-situ Adhesive-less Joining of Thermoplastics and Their Composites to Metals in Net-Shape Processes and an Integrated Design and Processing Education Plan

9501646拉马尼，这项研究的主要目标是开发原位工艺，以净成形工艺将热塑性复合材料与金属连接起来。模型环境将采用热熔法和模压成型法。工艺开发周期将包括表面准备、固化过程中的接触压力、加热和冷却速度、熔化和再结晶温度的保持时间、结合线厚度和均匀性的影响，以及提高耐久性的阳极氧化。残余应力将被建模为工艺参数的函数，进行验证，然后用于改进工艺。已知的表征技术X射线衍射仪(X射线衍射仪)、数字扫描量热仪(DSC)和扫描电子显微镜(SEM)将用于评估聚合物结晶度和界面结构。将确定接头的机械性能。然后将结果应用于纤维缠绕和注塑成型，并同时使用这些模型和实验表征进行优化。将确定掺入纤维对接头残余应力和性能的影响。初步的实验和建模结果令人鼓舞。感应加热将用于提高加工速度，减少聚合物在熔体中的停留时间，并使该工艺具有应用吸引力。在教学方面，将开发一门将设计和加工相结合的新课程。课程将综合运用工程基础、动手操作、建模、多媒体、跨学科经验和产业视角。进一步发展两用复合材料加工实验室。通过利用跨学科经验和已完成的研究，将加强双层复合材料加工课程的实验室部分。我们将与一位同事一起开发一门实践基础广泛的材料和制造工艺课程。这一教学方案的特点是开发了一门新的双级技术选修课，即“面向加工的设计”(DFP)，并与“虚拟加工实验室”(VPL)相结合。DFP课程将通过提供虚拟工艺体验，在设计和加工之间建立牢固的联系。本课程将整合演示、流程模型和计算机工具，以提供独特的体验来影响比动手课程更多的学生。实验室的本科教学计划、研究经验和高素质研究生的培养将产生广泛的影响，并服务于未来的行业需求。学生的研究和培训将通过在参与行业的暑期就业得到加强，这也将简化技术转让。在设计和加工方面的研究和教学相结合的方案将为学生提供独特的体验。通过选择三个不同的非竞争性协作行业，即生物医疗、汽车和航空航天，通过减少制造时间和步骤，可以在生物医疗植入物、悬挂连杆、机身结构和金属轴承套等应用中大幅降低组装、工具和加工成本。

9501646 Ramani The primary objective of this research is to develop in-situ processes to join thermoplastic composites to metals in net-shape processes. A hot-melt process and compression molding process will be used as model environments. The surface preparation, contact pressure during consolidation, heating and cooling rates, hold times at melt and recrystallization temperature, effect of bond line thickness and uniformity, and anodization to increase durability will be included in the process development cycle. The residual stresses will be modeled as a function of the process parameters, validated, and then used to improve the process. Known characterization techniques x-ray diffraction (XRD), digital scanning calorimetry (DSC) and scanning electron microscopy (SEM), will be used to evaluate the polymer crystallinity and structure of the interface. The mechanical properties of the joint will be determined. The results will then be applied to filament winding and injection molding and optimized using the models concurrently with experimental characterization. The effects incorporating fibers on the residual stresses and performance of the joint will be determined. Preliminary experimental and modeling results are encouraging. Induction heating will be incorporated to increase the process speeds, reduce polymer residence time at melt, and make the process attractive for applications. At the teaching front, a new curriculum that integrates design and processing will be developed. A synergistic combination of engineering fundamentals, hands-on, modeling, multi-media, inter-disciplinary experiences and industrial perspective will be used. A dual purpose composites processing laboratory will be developed further. The laboratory component of the dual-level composites processing course will be enhanced through the use of interdisciplinary experiences and completed research. A hands-on broad-based materials and manufacturing processes course will be developed with a colleague. The features that distinguish this teaching proposal are development of a new dual-level technical elective in "Design for Processing" (DFP) in conjunction with a "Virtual Processing Lab" (VPL). The DFP course will make strong linkages between design and processing by providing virtual process experiences. This course will integrate demonstrations, process models, and computer tools to provide unique experiences to impact a greater number of students than hands-on courses. The undergraduate teaching plan, research experiences, and training of highly qualified graduate students in the laboratory will have a broad impact and serve future needs of industry. Student research and training will be enhanced through summer employment in the participating industries which will also ease technology transfer. The combined research and teaching programs in design and processing will offer unique experiences to students. By selecting three diverse non-competitive collaborating industries, namely bio-medical, automotive and aerospace major reduction in assembly, tooling and processing costs by reducing the times and steps to manufacture may be seen in applications such as bio-medical implants, suspension linkages, airframe structures, and metal bearing sleeves.