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The aim of this project is the design and optimization of the formulation of epoxy adhesives for bonding metal to composite parts . This joints are most widely used in the aerospace industry to reduce stress concentration at a point. Joints for single edge joining include stainless steel metal with commercial code 316L and composite epoxy resin / carbon fiber. In this study, the effect of three types of additives: filler (alumina micro-particles), nylon 6.6 and phenolic resin (type of resin) on the mechanical and thermal properties of epoxy adhesive have been investigated. Tensile test results showed that increasing alumina fillers increases the tensile strength and overlap shear adhesive samples, respectively, in single lap joint dumbbells and elderly. The test showed that increasing the amount of nylon 6.6 When is slightly higher due to a sharp drop in tensile strength and overlap shear, respectively, in both cases is dog bone and single lap joint adhesives. This limit depends on the capacity epoxy ring to absorb amide hydrogens. The test for thermal properties (TGA) showed that increasing the amount of phenolic thermal stability is improved. High-temperature tensile test of appropriateness is also increasing impact of phenolic resin. Finally, the adhesive properties built with the similar adhesive (UHU) were compared. Results showed superiority in single lap joint metal to composite adhesive is made in the study.

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In the current work, a modified method of friction stir process (FSP) based on ultrasonic vibration and modified FSP tool design was developed to disperse multi-walled carbon nano-tube (MWCNT) throughout nylon 6 matrix. To this end, Field emission scanning electron microscopy, X-ray diffraction, Vickers’ micro-hardness, and visual inspection were used to evaluate the fabricated nano-composites. Also, a modified design of FSP tool together with ultrasonic vibration were used to improve the impact and efficiency of FSP. Several experiments were conducted to approach an optimum range of FSP parameters (rotational speed and traverse speed). The scanning electron microscopy observations and X-ray diffraction patterns (XRD) declare that MWCNT was dispersed homogeneously throughout nylon 6 matrix. Micro-hardness results illustrate that homogeneous dispersion of MWCNT throughout nylon 6 matrix results in 33% increase of micro-hardness. In general, the obtained results declare that ultrasonic vibration causes an increase in traverse speed and production speed of nano-composite without affecting the homogeneous dispersion and hardness of nano-particles throughout the matrix. Also, it is clear that ultrasonic vibrations did not noticeably affect superficial form of nano-composites due to low traverse speeds used in ultrasonic assisted friction stir process.