Search NASA⌕ Search

SEARCH · Search NASA

Results for “metal joining”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

126 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Structural basis for proficient oxidized ribonucleotide insertion in double strand break repair

Reactive oxygen species (ROS) oxidize cellular nucleotide pools and cause double strand breaks (DSBs). Non-homologous end-joining (NHEJ) attaches broken chromosomal ends together in mammalian cells. Ribonucleotide insertion by DNA polymerase (pol) μ prepares breaks for end-joining and this is required for successful NHEJ in vivo. We previously showed that pol μ lacks discrimination against oxidized dGTP (8-oxo-dGTP), that can lead to mutagenesis, cancer, aging and human disease. Here we reveal the structural basis for proficient oxidized ribonucleotide (8-oxo-rGTP) incorporation during DSB repair by pol μ. Time-lapse crystallography snapshots of structural intermediates during nucleotide insertion along with computational simulations reveal substrate, metal and side chain dynamics, that allow oxidized ribonucleotides to escape polymerase discrimination checkpoints. Abundant nucleotide pools, combined with inefficient sanitization and repair, implicate pol μ mediated oxidized ribonucleotide insertion as an emerging source of widespread persistent mutagenesis and genomic instability.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2025

Understanding Oxide–Metal Interactions During Hot Isostatic Pressing to Diffusion Bond Aluminum Alloy 6061 Plates

The interaction between Mg, Si, and Al 2 O 3 during hot isostatic pressing diffusion bonding of aluminum alloy 6061 (AA6061) plates was investigated through thermodynamic calculations and experimental microstructural characterization. Thermodynamic calculations as functions of temperature, pressure, and composition revealed that the interaction among Mg, Si, and Al 2 O 3 yields Mg 2 Si and either MgO + Al or MgAl 2 O 4 + Al, facilitating the reduction of Al 2 O 3 and allowing Al/Al metallic bonds to form. Total pressure variation had a negligible influence on the oxygen partial pressure, and consequently, the reaction product formation. Oxygen partial pressure variation as a function of temperature and initial amount of Al 2 O 3 determined the formation of either MgO or MgAl 2 O 4 . Experimental Hot Isostatic Pressure (HIP) bonding at 723 K and 833 K under a constant pressure of 1017 atm documented the cooling rate-dependent formation of β–Mg 2 Si precipitates. High-resolution transmission electron microscopy imaging and selected area electron diffraction patterns verified the formation of β–Mg 2 Si and MgO at the interface but did not detect MgAl 2 O 4 . In conclusion, findings from this study clarify the role of thermochemical interactions in oxide disruption and bonding mechanisms during HIP diffusion bonding of AA6061 and provide guidance for optimizing joining processes for monolithic nuclear fuel assemblies.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Interfacial reaction during friction stir assisted scribe welding of immiscible Fe and Mg alloy system

We report on interfacial characteristics and chemistry of bonded Mg-Fe interfaces welded using friction stir assisted scribe technique (FaST). Two pairs of dissimilar joints: (AZ31-DP590) and (Pure Mg-DP590) were studied to shed light on joining mechanisms responsible for bonding of “immiscible” pairs of Mg and Fe. We present first direct experimental evidence of presence of oxide layer, Al segregation by atom probe tomography and nano steel grains close to interface by transmission electron microscopy study.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Neutron Diffraction Residual Stress Study of a AA2219-T87 Self-Reacting Friction Stir Weld

2219-T87 is a precipitation hardenable aluminum-copper alloy which sees wide use in structural aerospace components. Thick panels of this alloy are joined via self-reacting friction welding (SRFSW); however, this thermomechanical process can result in significant loss of the alloy’s strengthening precipitates and large residual stresses which are detrimental to mechanical behavior and performance. High-resolution maps of the residual strain and stress states along the normal, transverse, and longitudinal directions of 2219-T87 SRFSW were obtained using neutron diffraction measurements. Residual stress had the highest tensile value in the heat-affected zone (HAZ) and the largest compressive stress in the base metal region of the normal and transverse directions. Line profile residual stress distributions displayed an “M”-shaped distribution in each direction with the longitudinal direction being the most pronounced while 2D residual stresses displayed an hourglass-shaped pattern. Further, average maximal longitudinal residual stress values ranged from 60.6 to 85.6% of yield. Microhardness testing across the transverse weld section produced a “V”-shaped curve with slight hardness recovery in the stir zone. Maximal and minimal microhardness values were observed in the base metal (154 HV) and thermomechanically affected zone (82 HV), respectively. Microstructural evolution was recorded using optical microscopy and showed decreasing grain size from the HAZ to the stir zone.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Microstructure and mechanical properties of friction stir weld performed on neutron-irradiated 304L steel with helium

As nuclear power plants (NPPs) approach or exceed 40–60 years of service, it may become necessary to repair damaged neutron-irradiated components to prolong longevity. However, fusion welding repair of irradiated steels and metallic materials is challenging because of helium-induced cracking. This study used friction stir welding (FSW) to address helium-related issues, such as helium bubble formation and grain boundary cracking. The microstructure, helium-induced degradation, and mechanical properties of a friction stir weld produced on neutron-irradiated 304L stainless steel with approximately 5.2 appm of helium were characterized. The analysis focused on variations in grain size, texture, and the morphology of helium-induced damage in the friction stir weld. Mechanical properties were characterized on the irradiated base metal (BM) and metallurgical zones of the friction stir weld: the stir zone (SZ), the thermo-mechanically affected zone (TMAZ), and the heat affected zone (HAZ). Only minor scattered porosity in the SZ and TMAZ and a few short microcracks (below 20 μm in length) in the TMAZ were observed, indicating limited helium-induced degradation. Tensile tests revealed good mechanical properties and fractography analysis demonstrated predominantly ductile fracture. In conclusion, the results highlight the immediate and substantial benefits of the FSW approach for repairing or joining helium-containing irradiated materials in NPPs.

36 MATERIALS SCIENCE↗
DOE OSTI2021

The McDonald Accelerating Stars Survey (MASS): White Dwarf Companions Accelerating the Sun-like Stars 12 Psc and HD 159062

We present the discovery of a white dwarf companion to the G1 V star 12 Psc found as part of a Keck adaptive optics imaging survey of long-term accelerating stars from the McDonald Observatory Planet Search Program. Twenty years of precise radial-velocity monitoring of 12 Psc with the Tull Spectrograph at the Harlan J. Smith telescope reveals a moderate radial acceleration (≈10 m s{sup −1} yr {sup −1}), which together with relative astrometry from Keck/NIRC2 and the astrometric acceleration between Hipparcos and Gaia DR2 yields a dynamical mass of M {sub B} = 0.605{sub −0.022}{sup +0.021} M {sub ⊙} for 12 Psc B, a semimajor axis of 40{sub −4}{sup +2} au, and an eccentricity of 0.84 ± 0.08. We also report an updated orbital fit of the white dwarf companion to the metal-poor (but barium-rich) G9 V dwarf HD 159062 based on new radial-velocity observations from the High-Resolution Spectrograph at the Hobby–Eberly Telescope and astrometry from Keck/NIRC2. A joint fit of the available relative astrometry, radial velocities, and tangential astrometric acceleration yields a dynamical mass of M {sub B} = 0.609{sub −0.011}{sup +0.010} M {sub ⊙} for HD 159062 B, a semimajor axis of 60{sub −7}{sup +5} au, and preference for circular orbits (e < 0.42 at 95% confidence). 12 Psc B and HD 159062 B join a small list of resolved Sirius-like benchmark white dwarfs with precise dynamical mass measurements which serve as valuable tests of white dwarf mass–radius cooling models and probes of AGB wind accretion onto their main-sequence companions.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Stability of zirconium hydride

This reports complete Milestone M2.2.1 Stability of zirconium hydride: Experimental investigation of the hydrogen concentration of encapsulated zirconium hydride before and after joining. In this milestone, we first report the successful fabrication of crack-free bulk zirconium hydride by using the ORNL static hydriding system. The fabricated hydride was characterized by using X-ray diffraction (XRD) and X-ray computed tomography (XCT). XRD results showed that the δ-phase zirconium hydride, α-zirconium, and ε-phase hydride were present. XCT confirmed the absence of the internal cracking. The hydrogen concentration was determined by the weight change before and after hydrogen loading, given the fact that the oxide phase was not found during XRD analysis. Two metallic cladding materials, i.e., molybdenum and FeCrAl, were selected to encapsulate the fabricated zirconium hydride pellets. Demonstration capsules were designed and machined. Mo crucible was successfully sealed by using a combination of electron beam welding and gas tungsten arc welding. Due to the undesired neutronics property of Mo, further investigation of this cladding material was not pursued. Electron beam welding and laser beam welding were employed to seal the FeCrAl capsules. XRD were performed on the zirconium hydride before and after the sealing. The results showed that the welding process has negligible impact on the hydrogen content in the FeCrAl-canned zirconium hydride. The presented work fulfilled the proposed work under this milestone and paves a pathway to fabricate single-phase zirconium hydride and to develop robust cladding materials to can bulk zirconium hydride.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Corrosion of Al-Fe self-pierce riveting joints with multiphysics-based modeling and experiments

Self-piercing riveting (SPR) is an extensively used joining technique to assemble dissimilar materials. However, this joining of the dissimilar materials can generate galvanic/crevice corrosion, which can drastically impact the mechanical properties and the service life of the joint. In this study, a multiphysics-based hybrid modeling approach is developed for the galvanic corrosion of the Al-Fe SPR joints, which can consider the corrosion initiation and corrosion evaluation jointly. Experimental studies are first performed to extract information regarding the corrosion initiation sites, corrosion evolution and overall corrosion induced material loss in SPR joints. The initiation information is then passed onto the multiphysics FE model thus making it a hybrid model. This model can help understand the influences of metal microstructure on the corrosion propagation while the morphology changes can also be analyzed. Using the developed hybrid modeling approach, thorough parametric studies can be performed to explore the coupled impacts of multiple corrosion factors on the corrosion behavior of the joints. The developed hybrid model is validated on the prediction of galvanic corrosion for the SPR joints by comparing with experimental observations.

36 MATERIALS SCIENCE↗
DOE OSTI2021

TOI-811b and TOI-852b: New Transiting Brown Dwarfs with Similar Masses and Very Different Radii and Ages from the TESS Mission

We report the discovery of two transiting brown dwarfs (BDs), TOI-811b and TOI-852b, from NASA’s Transiting Exoplanet Survey Satellite mission. These two transiting BDs have similar masses but very different radii and ages. Their host stars have similar masses, effective temperatures, and metallicities. The younger and larger transiting BD is TOI-811b at a mass of M {sub b} = 59.9 ± 13.0M {sub J} and radius of R {sub b} = 1.26 ± 0.06R {sub J}, and it orbits its host star in a period of P = 25.16551 ± 0.00004 days. We derive the host star’s age of 93{sub −29}{sup +61} Myr from an application of gyrochronology. The youth of this system, rather than external heating from its host star, is why this BD’s radius is relatively large. This constraint on the youth of TOI-811b allows us to test substellar mass–radius evolutionary models at young ages where the radius of BDs changes rapidly. TOI-852b has a similar mass at M {sub b} = 53.7 ± 1.4M {sub J} but is much older (4 or 8 Gyr, based on bimodal isochrone results of the host star) and is also smaller with a radius of R {sub b} = 0.83 ± 0.04R {sub J}. TOI-852b’s orbital period is P = 4.94561 ± 0.00008 days. TOI-852b joins the likes of other old transiting BDs that trace out the oldest substellar mass–radius evolutionary models where contraction of the BD’s radius slows and approaches a constant value. Both host stars have a mass of M {sub ⋆} = 1.32M {sub ⊙} ± 0.05 and differ in their radii, T {sub eff}, and [Fe/H], with TOI-811 having R {sub ⋆} = 1.27 ± 0.09R {sub ⊙}, T {sub eff} = 6107 ± 77 K, and [Fe/H] = + 0.40 ± 0.09 and TOI-852 having R {sub ⋆} = 1.71 ± 0.04R {sub ⊙}, T {sub eff} = 5768 ± 84 K, and [Fe/H] = + 0.33 ± 0.09. We take this opportunity to examine how TOI-811b and TOI-852b serve as test points for young and old substellar isochrones, respectively.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2020

TOI-481 b and TOI-892 b: Two Long-period Hot Jupiters from the Transiting Exoplanet Survey Satellite

We present the discovery of two new 10 day period giant planets from the Transiting Exoplanet Survey Satellite mission, whose masses were precisely determined using a wide diversity of ground-based facilities. TOI-481 b and TOI-892 b have similar radii (0.99 ± 0.01 R{sub J} and 1.07 ± 0.02 R{sub J}, respectively), and orbital periods (10.3311 days and 10.6266 days, respectively), but significantly different masses (1.53 ± 0.03 M{sub J} versus 0.95 ± 0.07 M{sub J}, respectively). Both planets orbit metal-rich stars ([Fe/H] = +0.26±0.05 dex and [Fe/H] = +0.24±0.05 for TOI-481 and TOI-892, respectively) but at different evolutionary stages. TOI-481 is a M{sub ⋆} = 1.14 ± 0.02 M{sub ⊙}, R{sub ⋆} = 1.66 ± 0.02 R{sub ⊙} G-type star (T{sub eff} = 5735±72 K), that with an age of 6.7 Gyr, is in the turn-off point of the main sequence. TOI-892 on the other hand, is a F-type dwarf star (T{sub eff} = 6261±80 K), which has a mass of M{sub ⋆} = 1.28 ± 0.03 M{sub ⊙} and a radius of R{sub ⋆} = 1.39 ± 0.02 R{sub ⊙}. TOI-481 b and TOI-892 b join the scarcely populated region of transiting gas giants with orbital periods longer than 10 days, which is important to constrain theories of the formation and structure of hot Jupiters.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2021

High-fidelity DNA ligation enforces accurate Okazaki fragment maturation during DNA replication

DNA ligase 1 (LIG1, Cdc9 in yeast) finalizes eukaryotic nuclear DNA replication by sealing Okazaki fragments using DNA end-joining reactions that strongly discriminate against incorrectly paired DNA substrates. Whether intrinsic ligation fidelity contributes to the accuracy of replication of the nuclear genome is unknown. Here, we show that an engineered low-fidelity LIG1 Cdc9 variant confers a novel mutator phenotype in yeast typified by the accumulation of single base insertion mutations in homonucleotide runs. The rate at which these additions are generated increases upon concomitant inactivation of DNA mismatch repair, or by inactivation of the Fen1 Rad27 Okazaki fragment maturation (OFM) nuclease. Biochemical and structural data establish that LIG1 Cdc9 normally avoids erroneous ligation of DNA polymerase slippage products, and this protection is compromised by mutation of a LIG1 Cdc9 high-fidelity metal binding site. Collectively, our data indicate that high-fidelity DNA ligation is required to prevent insertion mutations, and that this may be particularly critical following strand displacement synthesis during the completion of OFM.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Friction Stir Welding – an Advanced Approach to Repair Nuclear Power Plant Components

Solid phase joining technique friction stir welding (FSW) has been shown to mitigate helium-related issues in fusion welding of irradiated steels. Here, we present detailed characterization results of the first friction stir weld of an irradiated 304L stainless steel (SS) coupon contained 5.2 atomic parts per million (appm) helium. Scanning electron microscopy (SEM) was used to characterize a cross section specimen removed from the friction stir weld. No macro helium induced crack was observed at the analyzed cross-section, and only 1 – 1.5 µm size pores were found in the stir zone (SZ) and the thermal-mechanical affected zone (TMAZ). Moreover, some minor helium aggregations (Maximum ~20 µm in length) appeared along grain boundaries inside the TMAZ. Thereafter, miniature tensile specimens were extracted from the SZ, TMAZ and heat affected zone (HAZ), and base metal (BM) and tested. All welded specimens showed high total elongations (> 60%) and strengths (> 75% BM strengths). Overall, the weld made by FSW showed much better results comparing with traditional fusion welding on irradiated SS.

Tang, Wei↗
DOE OSTI2021

High Force Spring Clamp System

This is the Final Technical Report for the work by Hyperboloid LLC using SBIR Grant # DE-SC0019579. The work responded to US DOE SBIR Topics FY2019, Phase 1, Release 1, August 13 2018, Topic: 30. a. (2) SRF cavity joining techniques that create vacuum seals without resorting to the use of bolted flanges in order to minimize particulates. Hyperboloid LLC designed, developed and tested the High Force Spring Clamp System characterized in Patent US 9756715 that is aimed at solving this topic. The patent is held by Thomas Jefferson National Accelerator Facility. The flange bolts are substituted with exceptionally high force, binder-clip-like “C” Clamps. The clamps are opened and applied by hydraulic based tooling called “Clamp Openers” using particle minimization methods. Model 1 Clamp reached the goal of sealing the SRF industry standard hexagonal section, aluminum alloy gasket, leak-free on a research cavity as determined by a superfluid helium challenge, at 2 K for 2 assembly cycles. Descriptions include the ANSYS calculations that determine the size and shape of the clamp, the details of the Clamp Opener construction, particle counts from sealing flanges using both bolts and clamps. Model 2 Clamp, at half the size, needing a softer metallic gasket to be successful, is more readily adaptable to Cryomodule designs. It was tested, but a needs soft gasket development to be successful.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Core collapse supernova gravitational wave emission for progenitors of 9.6, 15, and 25 M ⊙

Here, we present gravitational wave emission predictions based on three core collapse supernova simulations corresponding to three different progenitor masses. The masses span a large range, between 9.6 and 25M ⊙ , are all initially nonrotating, and are of two metallicities: zero and solar. We compute both the temporal evolution of the gravitational wave strains for both the plus and the cross polarizations, as well as their spectral decomposition and characteristic strains. The temporal evolution of our zero metallicity 9.6M ⊙ progenitor model is distinct from the temporal evolution of our solar metallicity 15M ⊙ progenitor model and our zero metallicity 25M ⊙ progenitor model. In the former case, the high-frequency gravitational wave emission is largely confined to a brief time period ~75 ms after bounce, whereas in the latter two cases high-frequency emission does not commence until ~125 ms after bounce or later. The excitation mechanisms of the high-frequency emission in all three cases correspond to proto-neutron star convection and accretion onto the proto-neutron star from the convective gain layer above it, with the former playing the dominant role for most of the evolution. The low-frequency emission in all three models exhibits very similar behavior. At frequencies below ~250 Hz, gravitational waves are emitted by neutrino-driven convection and the standing accretion shock instability (SASI). This emission extends throughout the simulations when a gain region is present. In all three models, explosion is observed at ~125, ~500, and ~250 ms after bounce in the 9.6, 15, and 25M ⊙ progenitor models, respectively. At these times, the low-frequency gravitational wave emission is joined by very low-frequency emission, below ~10 Hz. These very low-frequency episodes are the result of explosion and begin at the above designated explosion times in each of our models. Our characteristic strains tell us that, in principle, all three gravitational wave signals would be detectable by current-generation detectors for a supernova at a distance of 10 kpc. However, our 9.6M ⊙ progenitor model is a significantly weaker source of gravitational waves, with strain amplitudes approximately 5–10 times less than in our other two models. The characteristic strain for this model tells us that such a supernova would be detectable only within a much more narrow frequency range around the maximum sensitivity of today’s detectors. Finally, in our 9.6M ⊙ progenitor model, we see very high-frequency gravitational radiation, extending up to ~2000 Hz. This feature results from the interaction of shock- and deleptonization-induced convection with perturbations introduced in the progenitor by nuclear burning during core collapse. While unique to the 9.6M ⊙ progenitor model analyzed here, this very high-frequency emission may, in fact, be a generic feature of the predictions for the gravitational wave emission from all core collapse supernova models when simulations are performed with three-dimensional progenitors.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2022

Characterization of the Fusion Zone in Laser Beam Welds on SS304L

Designing a welded joint requires consideration of the welding process, component/assembly structure and weld geometry, material composition, properties, and desired joint performance. The designer must also specify a set of acceptance criteria used to evaluate the welds. This study was conducted to support the design team responsible for specifying the spot weld profile by investigating the relationship between weld process parameters and the weld geometry and properties to further inform design optimization. The subjects of this study are two thin stainless steel 304L (SS304L) components joined by Laser Beam Welding (LBW). The components are the Housing, which contains flexible circuitry, and the Cover that protects the circuitry during handling, installation, and under service loads. Figure 1 illustrates coupon versions of the Cover and Housing used to simulate the interface between these components for weld testing. These coupon representations of assembly components were designed to match the material and relevant geometry related to the welded joint while other features not relevant to the welded joint are excluded.The objective of this study was to characterize the sensitivity of the weld geometry and mechanical properties to the input weld parameters to inform further Finite Element Analysis (FEA) efforts in balancing joint strength against assembly deformation caused by the welding process. Characterization was accomplished by varying laser welding parameters around the current design values and measuring weld geometry on the cross-sections. Nanoindentation with a spherical and flat-ended tip was used on polished section cuts of the weld to obtain direct estimates of the stress-strain response of the Fusion Zone (FZ) for comparison to the Base Metal (BM).

42 ENGINEERING↗
DOE OSTI2021

Unconventional Materials Processing Using Spark Plasma Sintering

Spark plasma sintering (SPS) has gained recognition in the last 20 years for its rapid densification of hard-to-sinter conventional and advanced materials, including metals, ceramics, polymers, and composites. Herein, we describe the unconventional usages of the SPS technique developed in the field. The potential of various new modifications in the SPS technique, from pressureless to the integration of a novel gas quenching system to extrusion, has led to SPS’ evolution into a completely new manufacturing tool. The SPS technique’s modifications have broadened its usability from merely a densification tool to the fabrication of complex-shaped components, advanced functional materials, functionally gradient materials, interconnected materials, and porous filter materials for real-life applications. The broader application achieved by modification of the SPS technique can provide an alternative to conventional powder metallurgy methods as a scalable manufacturing process. The future challenges and opportunities in this emerging research field have also been identified and presented.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Corrosion Control in Carbon Fiber Reinforced Plastic (CFRP) Composite-Aluminum Closure Panel Hem Joints

This project targeted the implementation of CFRP/Al closure panels as a drop-in replacement for all-aluminum closures used in automobile production today. The project focused on the development of corrosion fundamentals involving CFRP materials and the use of those materials in mixed-material joints. Numerous studies were completed to benchmark current materials and test mixed metal joints. Good correlation was found between outdoor exposures and laboratory cyclic corrosion testing. The insights from the corrosion testing fundamentals and benchmarking phases informed the development of low-cure adhesive and electrocoats and conductive primers for the CFRP. Adhesive and electrocoat materials were successfully developed meeting low-cure targets for bake (150C/10min). These materials were scaled-up and used to produce 5 prototype liftgates to further evaluate CFRP/Al joints in a full-scale part. The lower cure materials enabled mitigation of CTE mismatch and reduced the required bake temperature, resulting in reduced part distortion. Corrosion testing of the liftgates revealed unexpected increases in corrosion relative to the standard bake materials. While rigorous evaluation of the parts was not possible due to numerous complexities associated with prototype testing, the results provided significant insights into the material behavior of CFRP/Al joints. Key learnings from the project included a better understanding of the system complexity (interplay of substrate/primer conductivity, production of full-scale prototypes), advances in coating/adhesive design for low-cure applications involving CFRP, and advancement of corrosion test protocols for CFRP.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Multiple‐Repeated Plasma Surface Treatments for Significantly Improving Bonding Performance of Metal‐Carbon‐Fiber‐Reinforced Thermoplastic Polymer Dissimilar Adhesive Joints

This work investigates how multiple‐repeated plasma surface treatments can significantly enhance adhesively bonded metal‐carbon‐fiber‐reinforced thermoplastic polymer (CFRTP) dissimilar joints, a topic that has been rarely investigated compared to other parameters during the plasma treatment process. By conducting double cantilever beam tests on adhesively bonded AA6061‐carbon‐fiber‐reinforced polyphthalamide (CFRPPA) dissimilar joints, it is shown that the average Mode I specific fracture energy after 20 repetitions of the same plasma treatment, using processing parameters without noticeably changing surface roughness, can be improved and saturated up to almost 2000% compared to non‐treated joints and almost 240% compared to a single plasma treatment commonly used in the literature. The improvement can be attributed to the enhanced chemical bonding at the CFRPPA‐adhesive interface. This study is important for achieving strong bonding performance of CFRTP‐related structural joints using multiple plasma treatments, a simple and effective method.

36 MATERIALS SCIENCE↗