Automated Surface Preparation of Organic Matrix Composites for Structural Adhesive Bonding

ABSTRACT: An automated surface preparation process will be developed for improving the adhesive bonding of organic matrix composites. The process will utilize high-speed atmospheric pressure plasma to yield the strongest bonds possible, i.e., 100% cohesive failure within the epoxy adhesive. The automated process will replace the unreliable, manual abrasion techniques that have been used for surface preparation in the past. Atmospheric plasma treatment is safe, reliable, low-cost and has no environmental, health and safety concerns. When implemented across the DoD complex, this process will save the government millions in manufacturing costs, and will yield lighter, stronger and faster warefighter systems. BENEFIT: Joining technology is a major concern in aircraft manufacturing and repair. Current abrasion techniques used to prepare organic matrix composites for bonding are unreliable and yield joints of low strength. A new surface preparation process is proposed that uses atmospheric pressure plasma to clean and activate the composite surface for bonding. This process is automated, completely reliable and generates joints of maximum strength. The anticipated benefits are a highly reliable and cost effective joining technology that can be used in the manufacture and repair of jet aircraft, helicopters, satellites, and many other aerospace systems. A direct benefit will be the production of lighter weight and higher performance aircraft for commercial and military applications