Integrated Framework for Manufacturing, Design, and Monitoring of Composite-Bonded Joints: An Overview of the Results of the IDEA Project (MOST) †
Abstract
1. Introduction
- ○
- Implement an innovative pre-bonding surface treatment using chemical etching and scale the process to the industrial level. Lab tests will evaluate surface conditions and joint properties, followed by large-scale validation.
- ○
- Develop a structural design methodology for reliable bonded joints using a local approach and sub-modelling strategy, turning it into an industrial tool.
- ○
- Create a structural health monitoring (SHM) system based on thermographic techniques to ensure in-service safety and scalability to real components.
2. Etching Optimization and Process Scale-Up
2.1. Identification of the Optimal Etching Parameters
- ○
- MAT1: Adherends CC204 6K T800 T2/2 ER451; adhesive DP490.
- ○
- MAT2: Adherends C380 T700 2X2T; adhesive Betamate 2098.
2.2. Process Scale-Up and Application to a Component Prototype
3. Quasi-Static and Fatigue Tests
3.1. Results for MAT1
3.2. Results for MAT2
4. Modelling and Validation
5. Health Monitoring Systems
6. Conclusions
- (1)
- Increasing the technology readiness level (TRL) of previously developed lab-scale solutions for the chemical etching of composite-bonded joints, with the aim of enhancing bond strength and preventing the negative effects of contamination.
- (2)
- Developing a tool for the efficient application of a local model in industrial design workflows, aimed at assessing the static and fatigue strength of composite-bonded joints.
- (3)
- Defining strategies for the structural health monitoring (SHM) of composite-bonded joints, suitable for in-service applications on real components.
- ○
- Although preliminary tests showed an increase in joint strength following acid etching, the results from the scaled process did not reveal significant improvements. This is likely due to the higher overall quality of the bonding process, which resulted in failure primarily occurring within the adhesive or the adherends. Nevertheless, the etching treatment effectively eliminates potential surface contamination, thereby reducing the risk of weak bonds.
- ○
- The two-stage approach for calculating local stress fields proved to be highly accurate. The entire methodology, comprising both the model and the calculation approach, was successfully validated under both static and fatigue loading conditions. This represents a robust tool for more reliable bonded joint design, making it suitable for integration into industrial design workflows.
- ○
- IR-based SHM methods demonstrated reliability, even when using sensors with lower cost, size, and weight compared to lab-scale equipment such as cooled cameras. This marks an important step toward integrating these SHM techniques into real-world service conditions, enhancing the safety and reliability of composite-bonded structures.
Author Contributions
Funding
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Code | Overlap [mm] | Surface Treatment | Quasi-Static Strength τav,c [MPa] | Fatigue—Cycles to Failure |
---|---|---|---|---|
MAT1 | 15 | Etched | 23.75 ± 1.43 | 71,000 ± 24,000 |
Non-etched | 21.14 ± 1.69 | 110,000 ± 15,000 | ||
25 | Etched | 16.51 ± 2.15 | 70,000 ± 30,000 | |
Non-etched | 17.75 ± 1.60 | 106,000 ± 41,000 |
Code | Overlap [mm] | Surface Treatment | Quasi-Static Strength τav,c [MPa] | Fatigue—Cycles to Failure |
---|---|---|---|---|
MAT2 | 25 | Etched | 19.24 ± 0.35 | 35,000 ± 7700 |
Non-etched | 19.37 ± 0.56 | 29,500 ± 1100 |
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Quaresimin, M.; Carraro, P.A.; Lamon, F.; Avataneo, S.G.; Basso, M.; Merulla, A.; Galietti, U.; D’Accardi, E.; Palumbo, D.; De Agostinis, M.; et al. Integrated Framework for Manufacturing, Design, and Monitoring of Composite-Bonded Joints: An Overview of the Results of the IDEA Project (MOST). Eng. Proc. 2025, 85, 53. https://doi.org/10.3390/engproc2025085053
Quaresimin M, Carraro PA, Lamon F, Avataneo SG, Basso M, Merulla A, Galietti U, D’Accardi E, Palumbo D, De Agostinis M, et al. Integrated Framework for Manufacturing, Design, and Monitoring of Composite-Bonded Joints: An Overview of the Results of the IDEA Project (MOST). Engineering Proceedings. 2025; 85(1):53. https://doi.org/10.3390/engproc2025085053
Chicago/Turabian StyleQuaresimin, Marino, Paolo Andrea Carraro, Federico Lamon, Silvia Giovanna Avataneo, Matteo Basso, Andrea Merulla, Umberto Galietti, Ester D’Accardi, Davide Palumbo, Massimiliano De Agostinis, and et al. 2025. "Integrated Framework for Manufacturing, Design, and Monitoring of Composite-Bonded Joints: An Overview of the Results of the IDEA Project (MOST)" Engineering Proceedings 85, no. 1: 53. https://doi.org/10.3390/engproc2025085053
APA StyleQuaresimin, M., Carraro, P. A., Lamon, F., Avataneo, S. G., Basso, M., Merulla, A., Galietti, U., D’Accardi, E., Palumbo, D., De Agostinis, M., Mele, M., Ferraris, M., Benelli, A., & Pandey, K. (2025). Integrated Framework for Manufacturing, Design, and Monitoring of Composite-Bonded Joints: An Overview of the Results of the IDEA Project (MOST). Engineering Proceedings, 85(1), 53. https://doi.org/10.3390/engproc2025085053