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Title: Static and Fatigue Strength Evaluations for Bolted Composite/Steel Joints for Heavy Vehicle Chassis Components

Abstract

In May 2003, ORNL and PNNL began collaboration on a four year research effort focused on developing joining techniques to overcome the technical issues associated with joining lightweight materials in heavy vehicles. The initial focus of research is the development and validation of joint designs for a composite structural member attached to a metal member that satisfy the structural requirements both economically and reliably. Huck-bolting is a common joining method currently used in heavy truck chassis structures. The initial round of testing was conducted to establish a performance benchmark by evaluating the static and fatigue behavior of an existing steel/steel chassis joint at the single huck-bolt level. Both tension and shear loading conditions were considered, and the resulting static and fatigue strengths will be used to guide the joint design for a replacement composite/steel joint. A commercially available, pultruded composite material was chosen to study the generic issues related to composite/steel joints. Extren is produced by STRONGWELL, and it is a combination of fiberglass reinforcement and thermosetting polyester or vinyl ester resin systems. Extren sheets of 3.2 mm thick were joined to 1.4 mm SAE1008 steel sheets with a standard grade 5 bolt with 6.35 mm diameter. Both tension andmore » shear loading modes were considered for the single hybrid joint under static and fatigue loading conditions. Since fiberglass reinforced thermoset polymer composites are a non-homogenous material, their strengths and behavior are dependent upon the design of the composite and reinforcement. The Extren sheet stock was cut along the longitudinal direction to achieve maximum net-section strength. The effects of various manufacturing factors and operational conditions on the static and fatigue strength of the hybrid joint were modeled and experimentally verified. It was found that loading mode and washer size have significant influence on the static and fatigue strength of the hybrid joint. The effect of different fatigue test frequencies on the sample temperature and the resulting fatigue life was also examined.« less

Authors:
; ;
Publication Date:
Research Org.:
Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
15015113
Report Number(s):
PNNL-SA-42134
VT0502020; TRN: US200508%%363
DOE Contract Number:  
AC05-76RL01830
Resource Type:
Conference
Resource Relation:
Conference: 4th Annual SPE Automotive Composites Conference, Commercial Transport Session, Paper No. 3, 1-14
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; BENCHMARKS; COMPOSITE MATERIALS; DESIGN; ESTERS; FASTENERS; FIBERGLASS; MANUFACTURING; POLYESTERS; POLYMERS; RESINS; SHEAR; SOLAR PROTONS; STEELS; TESTING; VALIDATION; composites, hybrid joints

Citation Formats

Sun, Xin, Stephens, Elizabeth V, and Herling, Darrell R. Static and Fatigue Strength Evaluations for Bolted Composite/Steel Joints for Heavy Vehicle Chassis Components. United States: N. p., 2004. Web.
Sun, Xin, Stephens, Elizabeth V, & Herling, Darrell R. Static and Fatigue Strength Evaluations for Bolted Composite/Steel Joints for Heavy Vehicle Chassis Components. United States.
Sun, Xin, Stephens, Elizabeth V, and Herling, Darrell R. 2004. "Static and Fatigue Strength Evaluations for Bolted Composite/Steel Joints for Heavy Vehicle Chassis Components". United States.
@article{osti_15015113,
title = {Static and Fatigue Strength Evaluations for Bolted Composite/Steel Joints for Heavy Vehicle Chassis Components},
author = {Sun, Xin and Stephens, Elizabeth V and Herling, Darrell R},
abstractNote = {In May 2003, ORNL and PNNL began collaboration on a four year research effort focused on developing joining techniques to overcome the technical issues associated with joining lightweight materials in heavy vehicles. The initial focus of research is the development and validation of joint designs for a composite structural member attached to a metal member that satisfy the structural requirements both economically and reliably. Huck-bolting is a common joining method currently used in heavy truck chassis structures. The initial round of testing was conducted to establish a performance benchmark by evaluating the static and fatigue behavior of an existing steel/steel chassis joint at the single huck-bolt level. Both tension and shear loading conditions were considered, and the resulting static and fatigue strengths will be used to guide the joint design for a replacement composite/steel joint. A commercially available, pultruded composite material was chosen to study the generic issues related to composite/steel joints. Extren is produced by STRONGWELL, and it is a combination of fiberglass reinforcement and thermosetting polyester or vinyl ester resin systems. Extren sheets of 3.2 mm thick were joined to 1.4 mm SAE1008 steel sheets with a standard grade 5 bolt with 6.35 mm diameter. Both tension and shear loading modes were considered for the single hybrid joint under static and fatigue loading conditions. Since fiberglass reinforced thermoset polymer composites are a non-homogenous material, their strengths and behavior are dependent upon the design of the composite and reinforcement. The Extren sheet stock was cut along the longitudinal direction to achieve maximum net-section strength. The effects of various manufacturing factors and operational conditions on the static and fatigue strength of the hybrid joint were modeled and experimentally verified. It was found that loading mode and washer size have significant influence on the static and fatigue strength of the hybrid joint. The effect of different fatigue test frequencies on the sample temperature and the resulting fatigue life was also examined.},
doi = {},
url = {https://www.osti.gov/biblio/15015113}, journal = {},
number = ,
volume = ,
place = {United States},
year = {Tue Sep 14 00:00:00 EDT 2004},
month = {Tue Sep 14 00:00:00 EDT 2004}
}

Conference:
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