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Development of a design space for dissimilar materials joining in aerospace applications

Published online by Cambridge University Press:  29 November 2023

S. Ahmad Khan
Affiliation:
Aerospace Engineering Department, National University of Sciences and Technology (NUST) H-12, Islamabad, Pakistan
H. Liaqat
Affiliation:
Aerospace Engineering Department, National University of Sciences and Technology (NUST) H-12, Islamabad, Pakistan
F. Akram
Affiliation:
Aerospace Engineering Department, National University of Sciences and Technology (NUST) H-12, Islamabad, Pakistan
H. Ali Khan*
Affiliation:
Aerospace Engineering Department, National University of Sciences and Technology (NUST) H-12, Islamabad, Pakistan
*
Corresponding author: H. Ali Khan; Email: hakhan@cae.nust.edu.pk
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Abstract

This research paper presents an application of the integrated process and product design (IPPD) approach for selecting the best joint configuration for dissimilar material joining in the early product design phase. The proposed methodology integrates the multi-criteria decision making (MCDM) approach with quality function deployment (QFD) to identify the key criteria for joint selection, including load-carrying capacity, size, cost per joint, ease of manufacturing, time consumption and deformation. Three types of joints (rivet, weld and adhesive) and two hybrid joints (adhesive-weld and adhesive-rivet) are considered for three dissimilar material configurations: carbon fiber-reinforced plastic (CFRP) aluminum, CFRP steel, and aluminum-steel. QFD is utilised to transform job requirements into design criteria, and in the second phase, the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) is employed to choose the optimal joint configuration based on the weighted criteria acquired in the previous phase. The selected joint configuration is then validated through experimental study. The findings demonstrate that the proposed IPPD approach with QFD-TOPSIS techniques is highly effective for selecting mechanical joints for dissimilar material joining in the early design phase. The study concludes that the adhesive-rivet hybrid joint is the optimal solution among all alternatives. The proposed methodology can ultimately lead to improved product reliability and performance, as well as reduced development time and cost.

Information

Type
Research Article
Creative Commons
Creative Common License - CCCreative Common License - BY
This is an Open Access article, distributed under the terms of the Creative Commons Attribution licence (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted re-use, distribution and reproduction, provided the original article is properly cited.
Copyright
© The Author(s), 2023. Published by Cambridge University Press on behalf of Royal Aeronautical Society
Figure 0

Figure 1. Classification of selection methodologies for decision making.

Figure 1

Figure 2. Methodology for the selection of best fastening technology for dissimilar materials.

Figure 2

Figure 3. HOQ developed for dissimilar material joining.

Figure 3

Table 1. The decision matrix developed after implementing QFD technique

Figure 4

Table 2. Step 1 from TOPSIS normalised matrix

Figure 5

Figure 4. The criteria, alternatives and configuration selected for decision making.

Figure 6

Table 3. Weighted matrix evaluated as discussed in Step 2

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Table 4. Positive and negative ideal solutions identified from Step 3

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Table 5. Variations from ideal solutions

Figure 9

Table 6. Relative closeness of fastening techniques

Figure 10

Figure 5. Graphical representation of TOPSIS output for a composite-aluminum interaction.

Figure 11

Figure 6. Graphical representation of TOPSIS output for a steel-aluminum interaction.

Figure 12

Figure 7. Graphical representation of TOPSIS output for a composite-steel interaction.

Figure 13

Table 7. Mechanical properties of unidirectional T700S carbon fiber/ 3234 [2]

Figure 14

Table 8. Mechanical properties of aluminum and AS056 aluminum rivet [40]

Figure 15

Figure 8. (a) Schematic of the single rivet single lap joint. (b) Schematic of the single lap adhesive joint.

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Figure 9. Experimental procedures for the tensile testing of the riveted joints.

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Figure 10. Load displacement curve obtained through tensile testing for CFRP/AI (a) adhesive joints, (b) riveted joint, and (c) hybrid joint, (d) comparison of mechanical behaviour of all three configurations upto 3mm.

Figure 18

Figure 11. Fractures surface of the failed CFRP laminate (a) depicting bending and ply pull out from front view; (b) critical ply and delamination from side view; (c) first ply failure and fiber breakage from front view; (d) inter-facial adhesive failure and cohesive failure in adhesive joint.