To meet the high demand for lightweight energy-efficient and safe structures for transport applications, a current state-of-the-art light rail vehicle structure is under development that adopts a multi-material design strategy. This strategy creates the need for advanced multi-material joining technologies. The compatibility of the adhesive with a wide range of material types and the possibility of joining multi-material structures is also a key advantage to its success. In this paper, the feasibility of using either epoxy or polyurethane adhesive joining techniques applied to the multi-material vehicle structure is investigated. Importantly, consideration is given to the effect of variation in bond thickness for both families of structural adhesives. Multi-material adhesively bonded single lap joints with different adhesives of controlled bond thicknesses were manufactured and tested in order to experimentally assess the shear strength and stiffness. The torsional stiffness and natural frequency of the vehicle were modelled using a global two-dimensional finite element model (FEM) with different adhesive properties, and the obtained vehicle performances were further explained by the coupon-level experimental tests. The results showed that the vehicle using polyurethane adhesive with a target bond thickness of 1.0 mm allowed for optimal modal frequency and weight reduction.

This work investigates the application of a rapid variothermal moulding process for direct processing of a braided thermoplastic commingled yarn. The process uses locally controllable, responsive tooling which provides opportunities for optimum part quality and significantly reduced cycle times compared with conventional processes. The proposed process was used to directly manufacture hollow beam structures from dry commingled braided preforms. It was demonstrated that the cycle time using the rapid process was reduced by more than 90% as compared to a conventional bladder moulding process, resulting in a total cycle time of 14 min. Additionally, initial three point flexure test results indicated an improvement in the mechanical performance of the resultant parts as compared to the benchmark.

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