Bonding metallic structures

Current production aircraft include bonded structure designed up to 20 years ago as well as more recent designs on newer aircraft or derivatives. Materials, processes and design philosophy for metallic bonded structure have remained relatively stable over that period, while composite bonded structure has advanced significantly. Both will be reviewed and contrasted in the following sections. 

Repair. Repairs for damaged bonded structure can be either mechanical or adhesively bonded. Mechanical repairs are metallic doublers on one or both sides of a damaged component, held on by fasteners. The fasteners transfer the load through the doubler around the damaged site and restore part functionality. Although common for metal-to-metal bonded structure, mechanical repair of sandwich structure is rare because of the risk of further delamination. Unless the doubler and fasteners are perfectly sealed, water can travel into the honeycomb core eventually causing freeze-thaw damage and delamination. 

There are, of course, many more aspects of composite hardware design that differ from metallic bonded structure but do not necessarily involve adhesive bonding. For instance there are many types of reinforcement tape and fabric to choose from, the orientation of the plies must be chosen, the ply stackups must be balanced to avoid part warping after cure, a minimum number of plies must be used to prevent non-visible impact damage that significantly affects the load carrying capability of the part, etc. 

The serendipitous discovery of this compound has proven to be extremely important to our visions of possibilities for new metal-metal bonded structures in reduced oxide phases. In retrospect it is amazing that oxide phases containing molybdenum in oxidation states less than 4+ were essentially unknown and certainly structurally uncharacterized. The existence of the previously mentioned series M2 Mo30q and LiM Mo303 should have been a tip-off to an extensive chemistry for metal-metal bonded molybdenum oxide systems. Indeed, subsequent work has revealed a plethora of new compounds all of which (where structure has been determined) feature strong metal-metal bonding in either discrete cluster units or extended chain arrays. 

Tsipis, C.A. (2010) in Metal-Metal Bonding, Structure and Bonding Book Series, Vol. 136 (ed. G. Parkin), Springer, Berlin/Heidelberg, pp. 217-274. 

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