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

全球减少温室气体排放的趋势已经点燃了人们对轻质材料的兴趣，这种材料有望在汽车行业实现显着的市场增长。在铝合金和纤维增强聚合物等材料组合不断增加的推动下，寻找适用于多材料结构的连接技术成为聚光灯下的焦点。最近的发展表明，胶粘剂粘接可以取代传统的紧固方法，并可以显著减少组装时间和成本。然而，由于制造和服务缺陷可能导致灾难性的故障，人们对这项加入技术仍然缺乏信心。在添加剂制造和使用脉冲激光的表面处理领域的最新发展的推动下，申请人正在开发各种方法来阻止裂纹扩展和防止灾难性故障。所提出的方法针对接头的关键属性，即匹配层的几何形状(衬底体系结构)、粘合线的组成(粘合线体系结构)和界面结合状况(界面体系结构)。申请者研究的下一阶段，也就是拟议的发现计划的重点，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，Discovery计划将追求以下相互关联的短期目标：1)开发和优化用于轻质金属和复合材料粘接的激光前处理；2)研究可扩展的方法，利用设计好的粘合线制造耐损伤粘接接头；3)了解设计基板在多材料粘接接头脱粘机理中的作用。这项研究将使用滑铁卢广泛的材料加工和表征实验设施，包括由CFI资助的用于金属和聚合物表面制备的新的多波长激光平台。最先进的实验与先进的建模相结合，将为未来的轻量化和损伤容忍型结构铺平道路，这些结构将减少燃料消耗和排放。加拿大的好处是通过向汽车和航空航天公司(例如麦格纳、丰田、庞巴迪)等关键终端接收器直接转让技术而获得的。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行业所需的高度可取的技能集的培训，例如粘接、机械特性、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聘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.