ADHESIVE BONDING OF CARBON FIBER
REINFORCED PLASTIC TO ADVANCED
HIGH STRENGTH STEEL
PI: Zhili Feng, Oak Ridge National Laboratory
Co-PI: Kevin Simmons, Pacific Northwest National Laboratory
2018 DOE VTO Annual Merit Review
June 19, 2018
Project ID # MAT-137
This presentation does not contain any proprietary, confidential, or otherwise restricted
VTO Annualinformation
Merit Review MAT-137
OVERVIEW
Timeline Barriers
Start: Oct, 2017 Limited scientific understanding of joining
mechanisms for metal to composite joints
Finish: Sept, 2020
Few technologies exist for joining metals
20% Complete to composites
Low joint strength
Budget
Crack arrest resistance in crash
Project Funding – $2,025K Thermal expansion mismatch
FY18 - $675K Durability and environmental effects
FY19 - $675K
FY20 - $675K Partners
All proposed future work is subject to change Oak Ridge National Laboratory
based on funding levels Pacific Northwest National Laboratory
VTO Annual Merit Review MAT-137 2
RELEVANCE
EERE-VTO Goal:
By 2025, demonstrate a cost-effective 25% glider weight reduction at no
more than $5/lb saved by 2025 as compared to a 2012 baseline
Project Objectives
Early-stage R&D focusing on
Fundamental understanding of CFRP to AHSS adhesive bonding characteristics
at nano/micro scales;
Identify and explore innovative adhesive bonding concepts and approaches for
performance and productivity through scientific understanding
Develop better tools for adhesive bonding performance, joint design, and lifetime
prediction
Closely interact with the Interface by Design Task
Enable increased use of CFRP in multi-material body structure for weight
reduction
VTO Annual Merit Review MAT-137 3
FY18 MILESTONES
Milestone Name/Description End Date Type
Identify potential surface/interface engineering 12/30/2017 Quarterly Progress
Measure (Regular)
process/methodology for Interface-By-Design.
Down-select one or two potential processes for
feasibility investigation of interface engineering
Demonstrate completion of surface 6/30/2018 Quarterly Progress
Measure (Regular)
characterization of PP and Nylon CFRP and
DP980 steel to determine the surface chemistry
and surface morphology
Demonstration capability of electrical resistivity- 9/30/2018 Quarterly Progress
Measure (Regular)
based health monitoring of Steel/CFRP joints
VTO Annual Merit Review MAT-137 4
APPROACH
OVERALL PLAN FOR ADHESIVE BONDING OF CFRP-AHSS
ORNL PNNL
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ACCOMPLISHMENT
SURVEY OF DIFFERENT ADHESIVES
Wide range of shear strength and elongation of adhesives in literature
How will these factors contribute to metal to adhesive bonding?
* Data provided by three major automotive adhesive suppliers
VTO Annual Merit Review MAT-137 6
ACCOMPLISHMENT
EFFECTS OF CURING TEMPERATURE AND TIME
Steel/Adhesive #3/Steel Steel/ Adhesive #3/Steel
50 min 30 min
45 min 25 min
20 min
35 min
15 min
25 min
10 min
15 min 150 °C 175 °C
5 min 5 min
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ACCOMPLISHMENT
CHAIN MOBILITY: CFRP SURFACE DEFORMABILITY AND ADHESIVE
BONDING
TS-CFRP-2/AD #3/ TS-CFRP-2 TP-CFRP-BASF/AD #3/ TP-CFRP-BASF In-situ curing and
oscillatory shear
20 °C 20 °C
(After cured)
(After cured)
150 °C 150 °C
Adhesive
(L8513)
Tcuring > Tg Softening: changing surface energy/ adhesive bonding
Chain movement
TS-CFRP
Surface Surface Tg TS-CFRP-2
TP-CFRP_BASF
Polymer based composites
Curing temperature
window
VTO Annual Merit Review MAT-137 8
ACCOMPLISHMENT
INITIAL ADHESIVE BONDING TESTS OF CFRP-AHSS WITH DIFFERENT
ADHESIVES
Lap shear test revealed considerable differences in joint strength and failure modes
Adhesive #1 Adhesive #2 Adhesive #3
Material
Combination TSS TSS TSS Failure
Failure Mode/location Failure Mode/location
(kN/ MPa) (kN/ MPa) (kN/ MPa) Mode/location
DP980/DP980 20.8/ 33.3 • Cohesive 16.1 / 25.7 • Zn Delamination 20.3/32.5 • Cohesive
• Base CFRP
DP980/CFRP 8.7/14 • Base CFRP 13.1 / 21 • CFRP side adhesive 3.6/5.7 • Adhesive
• Zn delamination
• Adhesive • Base CFRP
CFRP -CFRP 4.7/ 7.6 11.3 / 18.8 3.4/5.4 • Adhesive
• Adhesive & CFRP • Partial Adhesive
• Bare DP980/1180: t=1.2mm; CFRP (PPA): t=3.1mm; Curing: supplier recommendations
DP980 DP980 DIC full strain field measurement of local deformation and failure
CFRP DP980
Cohesive failure
Base CFRP failure
High strain concentration at interface before fracture
DP980 CFRP CFRP
DP980
Adhesive failure
Propagation of CFRP failure
Zn Delamination Adhesive
failure
VTO Annual Merit Review MAT-137 9
ACCOMPLISHMENT
DEFORMATION AND FAILURE PROPOGATION AT ADHESIVE BOND
LINE AS REVEALED BY DIC LOCAL STRAIN FIELD MEASUREMENT
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RESPONSES TO PREVIOUS YEARS
REVIEWERS’ COMMENTS
Project is a new start in FY18.
No prior year comments to address.
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COLLABORATION AND COORDINATION
An integrated R&D team from ORNL and PNNL
Closely coordinated research activities and responsibilities as highlighted
in Approach on Page 4
Bi-weekly web meetings between research team members
Industry partners Dow Automotive, L&L, 3M, PPG provided adhesives
Core Research Team Members
ORNL: Zhili Feng, Amit Naskar, Yong Chae Lim, Jian Chen, Ngoc Nguyen,
David Warren, Xin Sun
PNNL: Kevin Simmons, Leo Fifield
VTO Annual Merit Review MAT-137 12
REMAINING CHALLENGES AND BARRIERS
Limited fundamental understanding of metal to CFRP
adhesive bonding characteristics at nano/micro scales;
Effects of surface conditions (morphology, chemistry) of substrates
Adhesive chemistry and additives, compatible to both AHSS and CRFP
Long-term performance and environmental degradations
Inhibition of galvanic corrosion,
Compatibility with CTE mismatch
Lack of scientifically sound, effective approaches to design
and engineering high performance adhesives and assembly
technologies
VTO Annual Merit Review MAT-137 13
PROPOSED FUTURE WORK
Continue on in-depth understanding on interface bonding, deformation
and roles of adhesive properties at nano/micro scales (FY18/19)
Connect to macroscopic level joint deformation and failure
Innovative surface modification technology (FY19)
Identify and develop surface modification concept based on above in-
depth understanding and interface by design for improved bonding
strength.
Develop processes that will effectively modify both the interface
morphology and interface chemistry
Adhesives tailored for metal to CFRP bonding (FY19/20)
Heath monitoring of curing/manufacturing process and structural
soundness in service (FY19/20)
Any proposed future work is subject to change based on funding levels
VTO Annual Merit Review MAT-137 14
SUMMARY
This early stage research focuses on the fundamental aspects of
adhesive bonding between CFRP to AHSS. In concert with the Interface
by Design Effort, innovative adhesive bonding concepts would be
identified and explored.
This project was initiated in FY18
Established overall R&D plan, schedule and material combinations
Quantified surface roughness and no-uniformity of CFRP
Determined cure kinetics, structure formation and thermomechanical
properties of CFRP and adhesives
Completed baseline study on the influence of adhesives on bonding strength
and failure modes
Initiated in-depth study on interface bonding, deformation and roles of
adhesive properties at nano/micro scales
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TECHNICAL BACKUP SLIDES
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DETAILED TASK PLANNING (GANTT CHART)
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COMPLEXITY OF ADHESIVE BONDING
❖ Multi-disciplinary topic
◆ surface chemistry
◆ Physics
◆ Rheology
◆ polymer chemistry
◆ stress analysis
◆ polymer physics
◆ fracture analysis
F. Awaja et al. / Progress in Polymer Science 34 (2009) 948–968
❖ Adhesion mechanisms
◆ Diffusion
◆ Mechanical
◆ molecular and chemical and thermodynamic adhesion phenomena
VTO Annual Merit Review MAT-137 18
ACCOMPLISHMENT
SURFACE ANALYSIS VIA TOF-SIMS, SURFACE CONTAMINATION
SO3- HSO4-
Before
After
• The SIMS spectra of 40%CF/ PA66 before and after Acetone/Alcohol/Water cleaning look similar;
• However, surface contamination, e.g., SO3- and HSO4- greatly decreases.
VTO Annual Merit Review MAT-137 19
ACCOMPLISHMENT
SURFACE ANALYSIS ON 40%CF-PA66 IM PLAQUE
Keyence Laser Profilometer Surface Roughness
Carbon fibers are easily differentiated in the
• Smooth region
• Average Ra=0.314 μm
energy dispersive spectroscopy (EDS)
• Max profile height Rz=18.116μm elemental mapping. Carbon, oxygen, and
• Rough region nitrogen were the elements observed
• Average Ra=2.213 μm
• Max profile height Rz=28.258 μm
VTO Annual Merit Review MAT-137 20
ACCOMPLISHMENT
SURFACE ROUGHNESS OF DP980 (BARE)
Sample Ra (um) Rz (um)
1 1.36 9.34
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ACCOMPLISHMENT
SURFACE CHARACTERIZATION OF GALVANNEALED
DP980 (45/45)
Top view
A B
B
compressed zeta phase (A) and crystallized zeta phase (B)
Cross section view
ζ FeZn13
𝛅 FeZn7
ζ
𝜞 Fe3Zn10
Steel
22
VTO Annual Merit Review MAT-137
ACCOMPLISHMENT
THERMOMECHANICAL PROPERTIES OF CFRP
TS-CFRP
(3-point bending with a ramp rate of 3 °C/min) TS-CFRP-2
TP-CFRP_BASF
Storage modulus at two selected
reference temperatures
(Unit: GPa)
Sample 150 °C 180 °C
TS-CFRP 10.1 3.8
TS-CFRP-2 3.1 2.1
TP-CFRP_BASF 4.3 3.9
VTO Annual Merit Review MAT-137 23
ACCOMPLISHMENT
GLASS TRANSITION TEMPERATURE OF CFRP
Glass transition temperatures determined by max G”
Sample Tg1 (°C) Tg2 (°C)
TS-CFRP -66.2 126.8/ 152.4
TS-CFRP-2 -61.9 135
TP-CFRP_BASF -58.1 64.2
Glass transition temperatures determined by max tan (δ)
Sample Tg1 (°C) Tg2 (°C)
TS-CFRP -63.2 131.1/158.7
TS-CFRP-2 -61.9 142
TP-CFRP_BASF -58.1 70.2
Note: The TS-CFRP has two thermal relaxation overlapped at Tg2
showing a very broad transition peak in both G” and tan (δ) graphs.
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TECHNOLOGY TRANSFER ACTIVITIES
Project is just starting.
No technology transfer activities to date.
Maintained close interactions with auto OEM and adhesive suppliers
Results and findings will be disseminated through publications
VTO Annual Merit Review MAT-137 25
