Influence of Voids on Dimensional Accuracy and Stability in Bonded Metal-Composite Hybrid Joints

Influence of Voids on Dimensional Accuracy and Stability in Bonded Metal-Composite Hybrid Joints

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This study investigates the impact of voids on the precision and dimensional stability of bonded joints in hybrid CFRP–aluminum assemblies for optical applications. Six CFRP samples were fabricated using filament winding and bonded to anodized aluminum alloy sleeves with DP 190 epoxy. Four samples were cured at 70 °C and two at 20 °C. Dimensional stability was assessed through radial runout measurements at three stages: post-manufacture, after environmental conditioning (including thermal cycling between +70 °C and –40 °C and six thermal shock cycles), and following mechanical resistance tests (shock, bump, and vibration per ISO 9022-3:2015). X-ray computed tomography (CT) revealed frequent defects such as adhesive starvation at joint edges, overflow, and a significant number of voids introduced during mixing. Porosity analysis showed that the presence of voids with equivalent diameters ≥0.5 mm strongly correlated with increased changes in radial runout, suggesting reduced dimensional stability.

This study investigates the impact of voids on the precision and dimensional stability of bonded joints in hybrid CFRP–aluminum assemblies for optical applications. Six CFRP samples were fabricated using filament winding and bonded to anodized aluminum alloy sleeves with DP 190 epoxy. Four samples were cured at 70 °C and two at 20 °C. Dimensional stability was assessed through radial runout measurements at three stages: post-manufacture, after environmental conditioning (including thermal cycling between +70 °C and –40 °C and six thermal shock cycles), and following mechanical resistance tests (shock, bump, and vibration per ISO 9022-3:2015). X-ray computed tomography (CT) revealed frequent defects such as adhesive starvation at joint edges, overflow, and a significant number of voids introduced during mixing. Porosity analysis showed that the presence of voids with equivalent diameters ≥0.5 mm strongly correlated with increased changes in radial runout, suggesting reduced dimensional stability.

carbon fibre | composite materials | computed tomography | epoxy | precision bonding | voids

carbon fibre | composite materials | computed tomography | epoxy | precision bonding | voids

KUPČÁK, R.; ZOUHAR, J.; PŘIKRYL, R.

01.12.2025

Trans Tech Publications Ltd

Solid State Phenomena

Solid State Phenomena

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