Engineering topics

Rodriguez, Brittany [ORNL] (ORCID:0009000895571987)

Publications and source records attributed to Rodriguez, Brittany [ORNL] (ORCID:0009000895571987).

4 records

DOE OSTI2026

Demonstration of high-rate manufacturing of π-joint using additive manufacturing

Bonded composite π-joints are critical to support wing geometries in aerospace/aircraft structures. Its lightweight and robust load-bearing capabilities/design guarantee high structural integrity and reliability. Current manufacturing techniques of π-joints are complex and laborious, and do not always offer high-quality joining. This study presents a high-rate manufacturing approach to fabricate π-joints using an integrated Additive Manufacturing and Compression Molding (AMCM) process. The joints were manufactured using unidirectional aerospace-grade LMPAEK/CF at 60% fiber loading for the stiffeners/skin and LM-PAEK/GF as the adhesive and characterized to evaluate their microstructure and strength. While the results indicate void formation at the joint caused by inadequate pressure, the peak tensile load of 600N recorded is akin to injection-autoclave molded π-joints, which validates the potential of this high-rate integrated approach to eliminate time-consuming and labour-intensive processes of making π-joints to reduce cost and produce high-quality joints.

Marathe, Umesh [ORNL]↗

DOE OSTI2026

Additively Reinforced Thermoformable PETG Composite Sheets for Improved Structural Efficiency

Thermoforming of short-fiber reinforced thermoplastic sheets offers a viable pathway for producing lightweight composite components; however, inherent anisotropy in fiber-reinforced sheets can limit structural performance under multidirectional loading. In this work, short carbon fiber, glass fiber, and hybrid fiber–reinforced PETG sheets were evaluated as candidate feedstock materials for thermoforming, with flexural and tensile testing performed both along the primary fiber direction and in the off-axis orientation to establish baseline stiffness, strength, and anisotropy. As expected, short carbon fiber PETG exhibited the highest stiffness and strength in the primary fiber direction, while all systems showed reduced performance in the off-axis direction. This off-axis performance reduction provides clear justification for the use of additive reinforcement when such thermoformed sheets are intended for structural applications. The intended manufacturing sequence involves thermoforming the reinforced sheet first, followed by the application of additively manufactured lattice reinforcement; therefore, the reinforcement strategy does not impose limitations on sheet formability during thermoforming. Post-forming lattice reinforcement significantly reduced load-normalized displacement by approximately 95–99% relative to non-reinforced sheets and improved weight-normalized stiffness by ~70%. These findings demonstrate that geometry-driven additive reinforcement can effectively compensate for off-axis property reductions in thermoformed PETG composites, enabling enhanced multidirectional structural performance without compromising manufacturability.

Talabi, Isaac [ORNL] (ORCID:0000000340215594)↗

DOE OSTI2026

Influence of Surface Treatment on the Interfacial and Mechanical Performance of Metal-Insert Overmolded Composites

Structural composites with metal inserts are gaining increasing interest enabling light weight design for energy efficiency, provide insulation, corrosion protection without compromising mechanical integrity. Such over molded metal-polymer composites show strong potential in many automotive and aerospace component parts, e.g. car bumper, chassis, door, brackets, fasteners, etc. Despite several advantages, metal-polymer dissimilar interface remains a weak spot in structural design, requiring further investigation to improve interfacial interlocking. The current work focuses on enhancing the metal-polymer adhesion between stainless steel inserts and polymer matrices (e.g. acrylonitrile butadiene styrene resin (ABS), and polyamide 66 (PA66) through surface treatment via chemical etching and mechanical roughening. In the chemical etching process, metal substrates were treated with aqua regia solution for different time intervals to evaluate surface roughness measured by water contact angle and morphology analysis. For mechanical roughening approach, metal inserts were subjected to blasting for surface abrasion. Treated samples were also functionalized with aminosilane coupling agent which showed successful grafting on the surface measured by water contact angle. Metal inserts with micro level surface roughness through etching exhibited significant 21% improvement in adhesion strength compared to untreated inserts; however, the effect of silane treatment on the interfacial strength was found to be highly matrix dependent.

Saha, Subhabrata [ORNL] (ORCID:000000033966064X)↗

DOE OSTI2025

Mechanical Properties and Interfacial Bonding of Overmolded Polymer Composite Lattice Structures

This study investigates the mechanical properties and interfacial bonding of Polyamide 12 filled with Glass Fiber (PA12/GF) lattice structures overmolded with Nylon 66 (PA66) and Thermoplastic Polyurethane (TPU). The PA12/GF lattices, designed in Gyroid, Isotruss, and Octahedral geometries, were produced using the Selective Laser Sintering (SLS) technique. The thermal characteristics of both the lattice and overmolding materials were analyzed using Differential Scanning Calorimetry (DSC) and Thermogravimetric Analysis (TGA). The mechanical performance and interfacial bonding were evaluated through mechanical testing and microstructural analysis. The results indicate that overmolding improved flexural strength and impact resistance of the PA12/GF lattices. For instance, the plain PA12/GF Isotruss lattice exhibited a flexural strength of 15.5 MPa. By overmolding it with TPU the flexural strength increased by up to 137%, while PA66-overmolding resulted in an increase of 371%, achieving a flexural strength of 73 MPa. In terms of impact resistance, TPU-overmolding improved performance significantly, with an increase of 1800% (Gyroid) compared to the plain lattice. Microstructural analysis revealed good adhesion at the interface, especially when both the lattice and overmolding materials were thoroughly dried prior to the overmolding process to minimize interfacial porosity. This study highlights the potential of using overmolding to enhance lattice structures performance, offering lightweight and cost-efficient solutions for automotive applications.

Talabi, Isaac [ORNL] (ORCID:0000000340215594)↗