Adjusting Part Dimensions for Bondline Control


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Jabus10
Jabus10
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Hi,

 For a student project I'm involved in we're bonding a large carbon fibre tube onto an aluminium insert. We've settled on using Hysol E-40HT due to its high temperature performance ( the assembly will encounter some quite high temperatures ) and it's quite easily available to us ( it also doesn't have the scary toxic fume warning that some of the Hysol datasheets have which is good as our student lab is in the basement of the engineering department and the ventilation is somewhat dismal).  In order to get the bondline gap of 0.1mm suggested in the datasheet we're mixing the epoxy with 0.004" glass beads.

 Do we need to adjust the dimensions of the aluminium insert in order to account for the 0.1mm gap required? Or do you simply push the CF tube onto the insert and hope that it stretches over some of the glass beads as you slide it on? The ID of the CF tube is 182mm and the aluminium insert is meant to be machined to max 181.985mm min 181.956mm (it's an H7g6 fit). Apologies for what is probably a really simple question but none of us have any practical composite experience. I imagine we'll have to make the aluminium insert have a 179.8mm diameter but then that gives alignment issues as the whole structure is about 3m long and the insert is at the base so if they're not quite concentric it will be very noticeable at the top.

 
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