Adhesives joining for Ultra-Stable structures

Adhesives joining for Ultra-Stable C/C Based Component and for Zerodur–CFRP–Zerodur sandwich structures for Aerospace Applications


This activity regards the development of high-performance adhesives to join components for aerospace applications: carbon fiber reinforced composites (C/C) and Zerodur to a carbon fiber reinforced polymers (CFRPs) honeycomb in a sandwich structure

Several different adhesive formulations, based on phenolic or cyanate-ester resins (charged with the maximum experimentally feasible amount of carbon-based fillers), are developed and tested, in order to guarantee sound mechanical strength, a low coefficient of thermal expansion, and ease of application on large components.

a) Results obtained at room temperature on adhesive joined C/Cs, b) Set up of the lap-shear test, c) a typical load/displacement curve: the line at 12 MPa evidences the minimum requested mechanical strength; the two selected adhesives are highlighted.

a) Sketch of the sandwich structure and b) the final prototype with face sheets made of Zerodur and CFRP honeycomb in between. The

adhesive joint between CFRPs and Zerodur is visible.

Phenolic adhesive bonded CFRPs: a) SEM polished cross sections at increased magnification showing the residual porosity in the phenolic adhesive, b,c) the perfect wettability at the adhesive–CFRPs interface. Inorganic charges in the phenolic adhesive are also visible in all the pictures.


Recent reference(s)

V.Casalegno, S. De la Pierre des Ambrois, I.Corazzari, F.Turci, P. Tatarko, O. Damiano, L. Cornillon, A.Terenzi, M. Natali, D. Puglia, L.Torre, M. Ferraris Design, Realization, and Characterization of Advanced Adhesives for Joining Ultra‐Stable C/C Based Components, Macromolecular Materials and Engineering, 2020, 305(9), 2000229,

De la Pierre des Ambrois, S.Corazzari, I.Damiano, O.,Cornillon L., Casalegno, V.Ferraris, M., Adhesive Joining of Zerodur–CFRP–Zerodur Sandwich Structures for Aerospace Applications Macromolecular Materials and Engineering, 2020, 2000464

DOI: 10.1002/mame.202000464