Bonding Carbon Fiber Sheet to Aluminum Plate?
Bonding Carbon Fiber Sheet to Aluminum Plate?
(OP)
Got a few ?'s about bonding carbon fiber sheets to an aluminum plate. This is a structural drive train part subject to high loads and vibration. The idea is to reinforce or stiffen a 6061 aluminum torque plate by bonding a carbon fiber laminate onto one or both sides. Im looking at pre made solid carbon quasi laminates without any core material that have a texture finish on one side for a bonding surface.
First question, is the textured epoxy bonding surface on the laminate sufficient to isolate the carbon and aluminum so there is no concern of galvanic corrosion (will be in a wet environment) or should I still consider a thin fiberglass layer between?
Second, any comments on the 3m DP-460, Hysol 9394, or E120HP for this purpose? My oven is too small to fit this part but I might be able to cure at elevated temps. Was also planning on a chromic acid ether to prep the Al and my buddy from Boeing suggested a BR-127 primer for the Al, any other prep concerns?
Thanks Much!
Ryan
First question, is the textured epoxy bonding surface on the laminate sufficient to isolate the carbon and aluminum so there is no concern of galvanic corrosion (will be in a wet environment) or should I still consider a thin fiberglass layer between?
Second, any comments on the 3m DP-460, Hysol 9394, or E120HP for this purpose? My oven is too small to fit this part but I might be able to cure at elevated temps. Was also planning on a chromic acid ether to prep the Al and my buddy from Boeing suggested a BR-127 primer for the Al, any other prep concerns?
Thanks Much!
Ryan





RE: Bonding Carbon Fiber Sheet to Aluminum Plate?
RE: Bonding Carbon Fiber Sheet to Aluminum Plate?
Mike Halloran
Pembroke Pines, FL, USA
RE: Bonding Carbon Fiber Sheet to Aluminum Plate?
If you are hell bent on doing it, put a layer of fiberglass between the
aluminum and the carbon fiber.
You may be better off looking at a rubber modified epoxy like Hysol EA9309 NA, the tensile will be lower , but the peel strength will be higher.
B.E.
The good engineer does not need to memorize every formula; he just needs to know where he can find them when he needs them. Old professor
RE: Bonding Carbon Fiber Sheet to Aluminum Plate?
http://solutions.3m.com/wps/portal/3M/en_US/Aerosp...
RE: Bonding Carbon Fiber Sheet to Aluminum Plate?
RE: Bonding Carbon Fiber Sheet to Aluminum Plate?
The reason for using a carbon laminate to stiffen the plate is mainly for weight (must be as light weight as possible) and there are clearance issues to moving drivetrain parts that limit how thick the plate can be. Basically, an Al plate that is thick enough wont fit and this plate must be very stiff. The tight fit also makes mechanical fastners a real problem.
Is the rubber modified epoxy like Hysol EA9309 NA to allow some give in the bond for expansion/contraction concerns? Would the fiberglass in between also help with this since its kind of a middle ground between the carbon and AL in terms of CLTE? I will have to double check with my buddy but I thought he said the BR-127 primer would also isolate the Al from the carbon to prevent corrosion...
Thanks again!
RE: Bonding Carbon Fiber Sheet to Aluminum Plate?
If you are going to the trouble of adding carbon fiber. with the constraints you have mentioned, you may be better off constructing the whole plate from carbon fiber and getting rid of the aluminum. You could also look at Titanium.
Yes the reason for suggesting rubber modified epoxy was to help your bond line and to up the peel strength, because of your expansion rate differences.
B.E.
The good engineer does not need to memorize every formula; he just needs to know where he can find them when he needs them. Old professor
RE: Bonding Carbon Fiber Sheet to Aluminum Plate?
RE: Bonding Carbon Fiber Sheet to Aluminum Plate?
Thanks again berk!