Bonding Carbon Fiber Tube To Aluminum

First suggested here in response to an op from me several years ago.

Bonding carbon fiber tube to aluminum.

What is the difference between the twill carbon fiber tubes and the ud carbon fiber tubes. Equally important was prepping the aluminum with the same steps. The seperation occurs between both the aluminum plate and the adhesive and the adhesive and carbon fiber. The simple answer just the exterior ply of material.

Next up was abrading the carbon fiber with 180 grit sandpaper to add tooth for the epoxy to key into. It is a 2 x3 aluminum plate bonded inside a carbon fiber square. The aluminum plate sees a fair amount of shock due to the application. Begin pressing the aluminum bondable component into the carbon fiber tube.

Depending on the intended use of the tubes i recommend reinforcing the outside of the tubing by winding on some kevlar tow with laminating epoxy over the part where the metal is bonded inside the tube. Only a small amount of force is required to fully seat the tube. Make sure that the component slides in straight and is not cocked off center. But did try it with a carbon rod telescoped into an alloy tube and it has never flinched.

A quick vacuum followed by more sanding in a few areas that where missed. With the ability to bond dissimilar multi materials including aluminum and carbon fiber composites you can use lighter and thinner materials for groundbreaking innovations in form and function. Our large diameter carbon fiber tubes are comprised of rolled bi directional woven carbon fiber. Unless noted on a specific product all of our carbon fiber tubing is made with ud prepreg on the inside and then will have either the ud exterior ply or a fabric ply.

Recent advances in multi material adhesives have given manufacturers new assembly options beyond traditional mechanical and thermal assembly methods. It is the only adhesive i tried that glues alu alloy to same for applications like a tube telescoped into a tube or a rod telescoped into a tube. Our carbon fiber large tubes come with a texture finish on both the inside and outside for easy bonding and painting. Another quick vacuum and acetone wipe down to remove any remaining dust oil and waxes.

In the case of bonding in tubing ends most of the mechanical load will be in directions where the tubing itself will carry most of the load. I am having issues bonding an aluminum plate to a carbon fiber structure. This tubing is designed for large applications such as telescope projects or light weight drums.