ADMACOM - Advanced manufacturing routes for metal/composite components for aerospace M. Ferraris, M. Salvo and ADMACOM TEAM* Department of Applied Science and Technology, Politecnico di Torino, Italy *www.admacomproject.eu The ADMACOM project Novel joining materials and techniques Participants Figure 9: Phase diagram Ta-Co [acc. Kaufman, 1991]. A wide number of ceramic matrix composites (CMC) and ceramics could be used right now to replace existing aerospace components, thus contributing to the increasing demand for novel components with improved properties such as light weight for reducing fuel consumption and CO2 emission. Project coordinator Ta based alloys and Co-Nb alloys Currently, their use is limited to very few applications because of the problem of joining them reliably. ADMACOM is a “Factory of the Future” project launched in October 2013 to develop innovative manufacturing technologies based on advanced design of interfaces and of joining materials for aerospace components. Components & Methodology Re-entry vehicle – joining of • C/SiC to C/SiC or Ti alloy • SiC/SiC to SiC/SiC or Ti alloy High temperature brazing alloys Ultrasonic soldering Design of joined component Reliability of mechanical joint + bonding properties of the joining material. Simple butt-joint configuration, Pressureless joining by glass-ceramics Mortise and Tenon joint configuration Half-lap joint Fibre reinforced composite Selective removal of the matrix or fibres Joining by Spark Plasma Sintering C/SiC CVD-SiC ESA’s IXV reentry vehicle www.esa.int rod tube actuator Joining material Metal Joining material Ti based joint Metal C/SiC Metal Surface engineering C/SiC with C/SiC pins fixed together and C/SiC with Ti alloy (MT Aerospace) Selective removal of SiC fbres from the SiC/SiC composite surface at POLITO Satellite – joining of • SiC to SiC or Invar and Ti alloy Silicon carbide space structures and instruments (AIRBUS group) SiC surface before and after laser structuring Max phases • Joining with a high purity Ti3SiC2 (≤ 2vol.% TiC and Ti3Si2) using Spark Plasma Sintering at controlled temperature and pressure in order to avoid a decomposition of Ti3SiC2. • In situ formation of interfacial MAX phase through a transient liquid phase using Al-Ti interlayers Laser structuring of SiC surface at AIRBUS Figure 5 SEM images of BOOSTEC SiC 100 material (quality “as sintered”) before (left) and after (right) laser based surface structuring Wetting tests and physical-chemical design of interfaces (CALPHAD calculations by using Thermocalc®) at CNR-IENI Characterisation Cyclic fatigue testing monolithic and joined test specimens (up to 1 Million Cycles in 28 hours) at EMPA Design and modelling of joined components Surface engineering CVD-SiC Metal Joined components Demo Shear strength tests Novel joining materials and techniques NEW WETTING TEST at Nanoforce, UK, by using Spark Plasma Sintering (SPS) up to to 2000-2300°C and at various heating rates. Characterisation Contacts Coordinator Prof. Monica Ferraris, Politecnico di Torino E-mail: monica.ferraris@polito.it www.admacomproject.eu/ The research leading to these results has received funding from the European Community's 7th Framework Programme FP7 2007-2013 under the grant agreement n. 609188.