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WRAP Theses Woodward 2018.Pdf A Thesis Submitted for the Degree of PhD at the University of Warwick Permanent WRAP URL: http://wrap.warwick.ac.uk/117448 Copyright and reuse: This thesis is made available online and is protected by original copyright. Please scroll down to view the document itself. Please refer to the repository record for this item for information to help you to cite it. Our policy information is available from the repository home page. For more information, please contact the WRAP Team at: [email protected] warwick.ac.uk/lib-publications Richard Woodward EngD Portfolio Innovation Report Towards high-volume, primary bonded, lightweight automotive structures. by Richard John Roy Woodward Innovation Report Submitted to the University of Warwick in partial fulfilment of the degree of Doctor15 February of Engineering 2016 Wednesday 31st October 2018 Richard Woodward EngD Portfolio Innovation Report Abstract Increasing pressures upon high-volume automotive manufacturers has led to the requirement for lightweight body structures. These increasingly require the introduction of lightweight materials, such as fibre reinforced polymer composites. As a result, effective joining technologies are a key automotive industry requirement to enable the introduction of optimal, lightweight material combinations to automotive body structures. Following an extensive literature review, adhesive bonding techniques were identified as a potentially suitable joining solution. However, two key barriers to the adoption of adhesive only, primary bonded, structural joints within the high-volume automotive industry were identified. These were the requirement for optimal surface treatment methods for composites, applied prior to adhesive bonding and a technique to achieve rapid joint handling strength during manufacture. These industrial requirements formed the primary areas of research for this project. An extensive investigation was performed to identify suitable surface pre-treatment methods, for high-volume adhesive bonding of composites. A particular focus was placed on the use of atmospheric pressure plasma surface treatment. It was identified that this process can effectively increase the surface free energy of both a thermoset and thermoplastic composite through modification of the surface chemistry. No significant increase in adhesive bond strength was found upon a thermoset substrate. The process can however effectively influence the adhesive joint failure mode upon a thermoplastic FRP surface, with joint durability implications. Limitations of the process were identified with respect to surface contamination removal. Electromagnetic induction heating was identified as a method to rapidly heat composite and metallic substrates. As such the process was potentially suitable for accelerating the cure and strength development of structural adhesives. Equipment was specified and a bespoke testing methodology developed to identify the rate of joint strength development following optimised induction heating cycles. A full sized CFRP floor/sill joint sub-assembly was used to demonstrate the achievable joint handling strength within a sub one-minute cure cycle for a primary bonded composite intensive joint. It was demonstrated that manufacturing cycle time limitations are achievable with a load well in excess of a typical body in white weight applied prior to joint failure. As a result, the work has identified and developed, a potential high-volume joining solution to a present challenge facing the automotive industry. i Richard Woodward EngD Portfolio Innovation Report Declaration This innovation report is submitted to the University of Warwick in support of my application for the degree of Engineering Doctorate. It has been composed by myself and has not been submitted in any previous application for any degree. The work presented (including data generated and data analysis) was carried out by the author. ii Richard Woodward EngD Portfolio Innovation Report Engineering doctorate supervisors Academic supervisors (WMG); Professor Ken Kendall and Dr Darren Hughes. Industrial supervisors (Jaguar Land Rover); Paul Bristo (2013 – 2016), Adrian Hughes (2013 – 2016) and Eissa Senan. iii Richard Woodward EngD Portfolio Innovation Report Table of contents Abstract ....................................................................................................................................... i Declaration ................................................................................................................................. ii Engineering doctorate supervisors ........................................................................................... iii Table of contents ...................................................................................................................... iv List of figures ............................................................................................................................ vii List of tables ............................................................................................................................. xii Nomenclature ......................................................................................................................... xiv Acknowledgments ................................................................................................................... xvi 1. Chapter one - Introduction ................................................................................................ 1 1.1. Research objectives ................................................................................................... 2 1.2. Portfolio and structure of this report ........................................................................ 3 2. Chapter two - Literature review ........................................................................................ 4 2.1. The driving force – emissions regulations ................................................................. 4 2.2. Multi-material body structures .................................................................................. 5 2.3. Automotive body joining ........................................................................................... 7 2.4. Joining methods for FRP intensive joints – a review ................................................. 8 2.4.1. Welding methods ............................................................................................... 8 2.4.2. Mechanical fasteners .......................................................................................13 2.4.3. Adhesive bonding techniques ..........................................................................17 2.5. Joint test methods ...................................................................................................28 2.6. Joining methods – conclusions ................................................................................29 2.7. Opportunities identified ..........................................................................................30 3. Chapter three - Atmospheric pressure plasma treatment ..............................................33 3.1. Investigation methodology ......................................................................................34 3.1.1. Treatment width assessment ...........................................................................38 3.1.2. Surface scanning electron microscopy ............................................................41 3.2. Epoxy thermoset CFRP APPT ....................................................................................42 3.2.1. Surface contamination removal .......................................................................47 3.2.2. Cataplasma durability testing ..........................................................................53 3.3. PA6 Thermoplastic APPT ..........................................................................................55 3.3.1. Durability assessment ......................................................................................62 3.3.2. Treatment standoff ..........................................................................................64 iv Richard Woodward EngD Portfolio Innovation Report 3.4. APPT XPS Thermoplastic and thermoset substrates. ...............................................66 3.5. APPT conclusions .....................................................................................................71 4. Chapter 4 - Rapidly cured primary bonded structures ....................................................74 4.1. Experimental methodology......................................................................................75 4.1.1. Initial testing methodology ..............................................................................76 4.1.2. Available induction heating equipment ...........................................................78 4.1.3. Adhesive selection ...........................................................................................78 4.1.4. Material considerations ...................................................................................80 4.2. Initial rapid curing data collection – TS-CFRP to TS-CFRP ........................................81 4.2.1. Bondline temperature distribution ..................................................................83 4.2.2. Thermogravimetric adhesive analysis ..............................................................86 4.3. Multi-material joint investigation – Aluminium to TS-CFRP
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