Dynamic Joining of Polymer Composites to Metal

Steel and aluminum plates can be joined to PMC plates using patented Dynamic Polymer Composite (DPC) techniques. Dynamic Joining begins with an edge-weldment to a metal plate. This edge is then dynamically mated to a super-plasticized strip of a composite panel. Adhesive plays a minor role. The result is a lap-joint more capable of tension, moment, shear, and impact than any hand lay-up. Analysis of a preliminary sample indicates that the failure mode is predictable and linear. A low-cost, high-production shipyard process is detailed. An innovative compensation for differential expansion is detailed that also distributes impact loadings. Repair and retrofit aboard ship are described. This work is based on twelve years of DPC development, six patents, and contracts funded by AF, MDA, Army SMDC, Boeing, and Pratt & Whitney. Structural applications considered for DPCs include airframes, cryogenic piping, radar towers, and hanger trusses. Phase I will develop, demonstrate, and test metal/PMC single and double lap joints at UDRI. Stresses will be modeled. Applications will be explored. Phase II will develop and test generic joints to validate a FE model. A specific Navy application will be designed, fabricated, demonstrated and tested. Technology transfer tools will be developed.