Work Package 3

The work in this WP will undertake the manufacture of metal/metal composite joints and in particular dissimilar aluminium alloys and aluminium/magnesium alloys.

Task 3.1 – Manufacture of metal / metal joints using nanoparticle fillers

This task will undertake the manufacture of dissimilar metal joints through friction stir welding (FSW). The filler materials developed in WP1 will be used to produce the dissimilar metal welds.

Task 3.2 – Ceramic coatings for corrosion protection of dissimilar metal welds

One of the major issues of dissimilar material joining is the corrosion behaviour at the joint interface. This task will investigate the incorporation of ceramic coats in the form of encrusted films applied onto the metal alloys prior to FSW for improved corrosion protection properties of the joined metals .

The ceramic coatings will be applied on the metal alloys via the dip coating process. Inorganic, organic or organically surface modified inorganic nanocontainers, nanotubes or nanoparticles will be incorporated into the ceramic coatings. All the nanocontainers and nanotubes will be loaded with organic or inorganic corrosion inhibitors.

Task 3.3 – Hybrid Organic-Inorganic Layers for corrosion protection of dissimilar metal joints

The corrosion issue will also be addressed through FSW Hybrid Organic-Inorganic Layers Hybrid organic layers including nanocontainers loaded with corrosion inhibitors will be synthesized.

Task 3.4 – Development of Non Destructive Evaluation technique for dissimilar metal joints

This task will undertake the development of reliable NDE techniques for the dissimilar metal joints. The incorporation of carbon nanotubes and corrosion inhibitors combined with the differing metallurgical morphology of the joined dissimilar metals presents a challenge to the NDE methodology to be implemented.