Aerospace composite material components are currently joined using heavy titanium bolts. This joining method is not ideal when considering its weight, thermal expansion, electrical conductivity, and risk of unbalanced load distribution. We propose here an innovative fastening technology using thermoplastic composite rivets. A rivet blank is heated above its melting temperature using Joule heating and is formed directly in the composite laminates by an automated process. Carbon fiber and polyamide blanks were used with two fiber architecture: 2D braid and unidirectional. The braided architecture showed superior manufacturing performance and repeatability. Joints were riveted in less than 40 s per rivet. The temperature measured in the riveted composite laminate in the vicinity of formed rivet reached only 136℃ during riveting. Double fastener lap shear testing showed breaking load of 6146 N per fastener. This joint strength is higher than comparable aluminum-riveted joints, and the specific joint strength is higher than titanium-bolted joints. With these advantages, the technology could be developed and used in the next generations of lighter, cleaner, and safer aircraft.

中文翻译：

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使用编织热塑性复合铆钉紧固复合结构

航空航天复合材料部件目前使用重型钛螺栓连接。考虑到其重量、热膨胀、导电性和负载分布不平衡的风险，这种连接方法并不理想。我们在此提出一种使用热塑性复合材料铆钉的创新紧固技术。使用焦耳加热将铆钉坯加热到其熔化温度以上，并通过自动化过程直接在复合层压板中形成。碳纤维和聚酰胺坯料用于两种纤维结构：二维编织和单向。编织结构显示出卓越的制造性能和可重复性。每个铆钉的铆接时间不到 40 秒。在铆接过程中，在成型铆钉附近的铆接复合层压板中测得的温度仅达到136℃。双紧固件搭接剪切测试显示每个紧固件的断裂载荷为 6146 N。这种接头强度高于同类铝铆接头，比接头强度高于钛螺栓接头。凭借这些优势，该技术可以开发并用于下一代更轻、更清洁、更安全的飞机。