Luigi Calabrese

Failure Map of Composite Laminate Mechanical Joint

The aim of this research is to investigate the pin/hole contact stress of a composite laminate and failure modes when submitted to tensile bearing tests. The limit loads and failure modes are evaluated as a function of pin diameter and hole position. Analyzing the joint geometry effect on the fracture mechanisms, a failure map is obtained, identifying three regions of typical failure modes of mechanically fastened joints. A theoretical approach is proposed to identify the field of each fracture mode to obtain a simple experimental methodology to support the design of a particular joint laminate. In addition, a simplified numerical model is proposed to evaluate near the hole the stress/strain distribution under tensile bearing load. This allows one to better understand the relevant dependence of the failure modes from the geometry of the joint for a given composite laminate.

Effect of galvanic corrosion on durability of aluminium/steel self-piercing rivet joints

Abstract Galvanic corrosion of steel/aluminium hybrid joints, obtained by self-piercing riveting technique, was investigated. Potentiodynamic polarisation tests, performed in 3·5 wt-% NaCl solution, evidenced the anodic and cathodic behaviour of metal constituent of the joints. Furthermore, long term aging tests were performed to evaluate the relationship among failure mechanism, joint configuration and corrosion damage in salt spray environment. The experimental results evidenced that the degradation phenomena influenced significantly performances and failure mechanisms of the joints, inducing premature failure of the joint at lower stress level at increasing aging time. Furthermore a theoretical model was proposed to forecast failure modes. Based on this model a simplified map of failure mechanisms promoted by corrosion phenomena has been drawn.

Fiber Reinforced Polyester Resins Polymerized by Microwave Source

Polyester resin based composite materials are widely used in the manufacture of fiberglass boats. Production time of fiberglass laminate components could be strongly reduced by using an intense energy source as well as microwaves. In this work a polyester resin was used with 2% by weight of catalyst and reinforced with chopped or woven glass fabric. Pure resin and composite samples were cured by microwaves exposition for different radiation times. A three point bending test was performed on all the cured samples by using an universal testing machine and the resulting fracture surfaces were observed by means of scanning electron microscopy (SEM). The results of mechanical and microscopy analyses evidenced that microwave activation lowers curing time of the composite while good mechanical properties were retained. Microwaves exposition time is crucial for mechanical performance of the composite. It was evidenced that short exposition times suffice for resin activation while long exposure times cause fast cross linking and premature matrix fracture. Furthermore high-radiation times induce bubbles growth or defects nucleation within the sample, decreasing composite performance. On the basis of such results microwave curing activation of polyester resin based composites could be proposed as a valid alternative method for faster processing of laminated materials employed for large-scale applications.

Synthesis of SAPO-34/graphite composites for low temperature heat adsorption pumps

Low temperature heat adsorption pumps represent the innovative cooling systems, where cold is generated through adsorption/desorption cycle of water by a suitable adsorbent with good adsorption and high thermal conductive properties. In this work, the hydrothermal synthesis of zeolite SAPO-34 on thermal conductive graphitic supports, aiming at the development of highly performing adsorbent materials, is reported. The synthesis was carried out using as-received and oxidized commercial carbon papers, and graphite plate. Composites were characterized by XRD, SEM and also by a thermogravimetric method, using a Cahn microbalance. The water adsorbing capacity showed typical S-shape trend and the maximum water loading was around 25 wt%, a value close to water adsorption capability of pure SAPO-34. These results are very promising for their application in heat adsorption pumps.

Three-Point Flexural Behaviour of GFRP Sandwich Composites: A Failure Map

In this work, the failure mechanisms of GFRP/PVC foam core sandwich structures subjected to three-point bending are analysed. By varying the skin thickness (t) and the span length between supports (l), experimental tests were carried out in order to find the relationship between the geometrical configuration of the sandwiches and the failure mechanism. By plotting failure mechanism on a graph of l against t, a failure map was created identifying the three typical failure mode regions of these sandwiches. The graph clearly shows the failure mode corresponding to each combination of l and t. To help optimise the use of these sandwich beams as structural elements, a theoretical failure mode map was constructed. The theoretical model results were consistent with the experimental ones, and so we can conclude that the theoretical model is a reliable predictor of failure mechanisms in sandwiches with defined geometry.

Pull-off adhesion of hybrid glass-steel adhesive joints in salt fog environment

Abstract The aim of this paper was to evaluate the durability behaviour of glass/steel adhesive joints exposed to salt fog environmental conditions for ten weeks, according to ASTM B117 standard. To this scope, pull-off mechanical tests were carried out in order to evaluate the performances evolution and damage phenomena of the adhesive joints during the ageing exposition. Two different types of adhesives were compared (i.e. epoxy and polyurethane ones). Moreover, the effects of the glass surface condition and the presence of a basalt mat layer within the adhesive thickness were evaluated. The mechanical performances were related with the occurred failure mechanisms. Epoxy-based joints showed higher strength and durability than the polyurethane based ones. Furthermore, frosted glass surface condition and basalt interlayer addition enhanced mechanical durability in salt fog environment of glass–metal dissimilar joints.

Corrosion Resistance of Cerium Based Silane-Zeolite Coatings on AA6061 Alloy

In the present work we analyzed the anti-corrosive properties, on AA6061, of sol-gel silane-zeolite hybrid coatings doped with cerium nitrate ions as inhibitor. Three different types of composite coatings were prepared by using cerium doped zeolite and/or silane matrix. For each type, four formulations, varying the zeolite amount (in the range 60-90% wt), were tested. All composite coating evidenced a high homogeneity and good adhesion performances. Cerium addiction in the coating formulation did not compromise the hydrophobic properties of the coating. Furthermore the addition of the cerium ions improved the anti-corrosion properties of the composite films inducing a significant stability of the electrochemical behavior.

Enhancement of the hydrophobic and anti-corrosion properties of a composite zeolite coating on Al6061 substrate by modification of silane matrix

Anti-corrosion properties of a silane–zeolite composite coating applied to aluminium substrates have been investigated. The composite film was prepared with different silane matrix formulations (varying bi-functional and tri-functional silane ratios). The results showed high hydrophobicity of the modified silane–zeolite coatings. Corrosion protection performance, during immersion in 3.5% NaCl solution, was evaluated by means of polarisation and electrochemical impedance spectroscopy tests. The polarisation curves evidenced a good corrosion resistance of all composite coating; though at high content of bi-functional silane, a reduction of corrosion protection performance was observed. At long immersion time (until 150 days), only the composite coating with low amount of bi-functional silane still evidenced good barrier properties.

Assessment of hydrophobic and anticorrosion properties of composite silane–zeolite coatings on aluminum substrate

The effect of matrix compounds on the behavior of silane–zeolite composite coatings on a 6061 aluminum alloy was evaluated by electrochemical test performed at long immersion time in 3.5% NaCl solution. It was observed that silane chains influence the hydrophobic behavior and the electrochemical performances of the zeolite-based composite coating. All composite coatings showed a long-term protection action in 3.5% NaCl solution. The use of silane compounds with long alkyl chain or with bi-hydroxyl groups made it possible to obtain electrochemically stable coating during long immersion time. Best results have been obtained with a multicomponent silane mixture (short and long molecular chains).

Electrochemical Impedance Spectroscopy Behaviour of NdFeB Coated Magnets in Saliva Solution for Orthodontic Applications

In this work the assessment of the corrosion performances in saliva solution of NdFeB magnets coated with silane layers was studied for its application in orthodontic brackets. The silane film, deposited by dip coating technique, has been prepared with varying dipping steps, with the purpose to identify the number of layers able to achieve an optimal protective action. Corrosion protection performance, during immersion in Fusayama synthetic saliva solution, was evaluated by means electrochemical impedance spectroscopy (EIS). The silane coatings evidenced good barrier properties resulting in an improvement of the anti-corrosion performances of the magnets. Better results were observed for samples with at least 15 layers of silane, that evidenced still acceptable protective action after three days of immersion in a Fusayama synthetic saliva solution.