1.0 Overview

• Different materials and mounting methods are explored to determine an optimal choice for the structural panel solution.

• These panels will be installed along the longitudinal planes of the chassis.

2.0 Summary of Options

Possible panel materials are listed below along with suggested mounting methods.

The suggesting mounting methods will likely require additional tabs to be installed onto the chassis.

* tabs must have sufficient bonding area

** fasteners need to be compatible with CF sandwich panels

2.1 Why is aluminium difficult to weld to steel?

https://www.twi-global.com/technical-knowledge/faqs/aluminium-welding/aluminium-to-steel#:~:text=Aluminium%20alloys%20can%20be%20joined,alloys%20to%20steel%20is%20difficult.

• Aluminium and steel vary in thermal conductivity and melting temperature

  • Tm_steel = 1370 C compared to Tm_Al = 660 C (~2X difference)

• the metals are insoluble in each other

• in the molten state, they react to form brittle intermetallic phases

• Since welded joints between aluminium and steel raise many issues, we can conclude that this option is not suitable for our application.

• However, there are other options for mounting aluminium to steel (adhesive bonding, mechanical fasteners )

3.0 Comparing Options

1 → 3 (worst to best)

* Need to know more about weight. It is not an issue unless it surpasses the weight limit (see S2021 Updated Masses of Sub-Team Assemblies ). We can remove weight as a criterion if the limit is not surpassed.

3.1 Discussion

• If it is determined that weight is not a critical factor, the best option would be steel sheet metal. Its main advantages are ease of installation and overall reliability.

• The only advantage of using carbon fibre is the weight savings.

• The advantages of aluminium over steel are weight savings and cost. However, this option presents challenges in the installation stage.

4.0 Conclusions