Resistance-welded thermoset composites: A Bayesian approach to process optimisation for improved fracture toughness

Thomas Maierhofer; Evros Loukaides; Craig Carr; Chiara Bisagni; Richard Butler

doi:10.1016/j.compositesa.2023.107894

Resistance-welded thermoset composites: A Bayesian approach to process optimisation for improved fracture toughness

Thomas Maierhofer, Evros Loukaides, Craig Carr, Chiara Bisagni, Richard Butler

Research output: Contribution to journal › Article › peer-review

1 Citation (SciVal)

Abstract

Joining thermoset composites via resistance welding offers a novel highly efficient assembly method for next-generation aerospace structures. Resistance-welded joints combine the benefits of bonding with the capacity for high-volume manufacturing rates and eliminate the need for complex surface preparation. The influence of key welding parameters on the joint performance is investigated by assessing the Mode I fracture toughness. Double Cantilever Beam specimens with different welding parameter combinations are manufactured, tested and compared with each other. Thermoset laminates are made weldable by co-curing a chemically compatible thermoplastic film with an uncured thermoset laminate. A Bayesian approach is used to study the correlation between processing parameters and to select parameters yielding high performance by training a Gaussian process emulator. Observed Mode I fracture toughness values are comparable to high-performance thermoplastic composites. This is equivalent to an improvement of approximately 290% in Mode I fracture toughness when compared to a co-cured thermoset joint.

Original language	English
Article number	107894
Number of pages	12
Journal	Composites Part A: Applied Science and Manufacturing
Volume	177
Early online date	18 Nov 2023
DOIs	https://doi.org/10.1016/j.compositesa.2023.107894
Publication status	Published - 28 Feb 2024

Bibliographical note

Funding Information:
This work was supported by the UKRI - Engineering and Physical Sciences Research Council, United Kingdom , Grant ‘Certification for Design - Reshaping the Testing Pyramid’ EP/S017038/1.

Funding Information:
The authors gratefully acknowledge the continuous project support and industrial guidance by GKN Aerospace UK. This research project was supported by the EPSRC, UK, Programme Grant: “Certification for Design: Reshaping the Testing Pyramid” (CerTest, EP/S017038/1). The authors would also like to thank Carl Scarth and Evangelos Evangelou (both University of Bath) for their support and advice on Gaussian processes.

Funding Information:
The authors gratefully acknowledge the continuous project support and industrial guidance by GKN Aerospace UK. This research project was supported by the EPSRC, UK , Programme Grant: “Certification for Design: Reshaping the Testing Pyramid” (CerTest, EP/S017038/1 ). The authors would also like to thank Carl Scarth and Evangelos Evangelou (both University of Bath) for their support and advice on Gaussian processes.

Keywords

A. Thermosetting resin
B. Fracture toughness
C. Statistical properties/methods
E. Fusion bonding
E. Joints/joining

ASJC Scopus subject areas

Mechanics of Materials
Ceramics and Composites

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10.1016/j.compositesa.2023.107894Licence: CC BY

Cite this

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title = "Resistance-welded thermoset composites: A Bayesian approach to process optimisation for improved fracture toughness",

abstract = "Joining thermoset composites via resistance welding offers a novel highly efficient assembly method for next-generation aerospace structures. Resistance-welded joints combine the benefits of bonding with the capacity for high-volume manufacturing rates and eliminate the need for complex surface preparation. The influence of key welding parameters on the joint performance is investigated by assessing the Mode I fracture toughness. Double Cantilever Beam specimens with different welding parameter combinations are manufactured, tested and compared with each other. Thermoset laminates are made weldable by co-curing a chemically compatible thermoplastic film with an uncured thermoset laminate. A Bayesian approach is used to study the correlation between processing parameters and to select parameters yielding high performance by training a Gaussian process emulator. Observed Mode I fracture toughness values are comparable to high-performance thermoplastic composites. This is equivalent to an improvement of approximately 290% in Mode I fracture toughness when compared to a co-cured thermoset joint.",

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note = "Funding Information: This work was supported by the UKRI - Engineering and Physical Sciences Research Council, United Kingdom , Grant {\textquoteleft}Certification for Design - Reshaping the Testing Pyramid{\textquoteright} EP/S017038/1. Funding Information: The authors gratefully acknowledge the continuous project support and industrial guidance by GKN Aerospace UK. This research project was supported by the EPSRC, UK, Programme Grant: “Certification for Design: Reshaping the Testing Pyramid” (CerTest, EP/S017038/1). The authors would also like to thank Carl Scarth and Evangelos Evangelou (both University of Bath) for their support and advice on Gaussian processes. Funding Information: The authors gratefully acknowledge the continuous project support and industrial guidance by GKN Aerospace UK. This research project was supported by the EPSRC, UK , Programme Grant: “Certification for Design: Reshaping the Testing Pyramid” (CerTest, EP/S017038/1 ). The authors would also like to thank Carl Scarth and Evangelos Evangelou (both University of Bath) for their support and advice on Gaussian processes. ",

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AU - Bisagni, Chiara

AU - Butler, Richard

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Resistance-welded thermoset composites: A Bayesian approach to process optimisation for improved fracture toughness

Abstract

Bibliographical note

Keywords

ASJC Scopus subject areas

Access to Document

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Re-shaping the Test Pyramid

Cite this

Resistance-welded thermoset composites: A Bayesian approach to process optimisation for improved fracture toughness

Abstract

Bibliographical note

Keywords

ASJC Scopus subject areas

Access to Document

Other files and links

Fingerprint

Projects

Re-shaping the Test Pyramid

Cite this