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  • Mechanical Tests

    • Tensile Test- needed for plug

      • How to test it

      • Probably not needed since the push rod will be under constant compression

    • Flexural Test

      • three-point and four-point bend testing according to ISO 14,125, ISO 178, ASTM D 790, and ASTM D 6272

      • parameters for this test are the support span, the speed of the loading, and the maximum deflection for the test

    • Impact Test

    • Compression Test

      • End loading

      • Sheer loading

      • ASTM D 695, ASTM D 3410, and ISO 14,126.

      • information on elastic limit, proportional limit, yield point, yield strength, and compressive strength

  • Strength at high temperatures (Summer)

  • Fatigue Failure?

Insert Testing

  • Adhesive

    • EA E-40HT

      • strength tapers off pretty fast around 40 degree celsius

      • Lap shear strength: 3740 psi, 26 N/mm^2

    • DP420

      • Etched Aluminum Strength Test: 4500 psi

      • Couldn’t find temp to % strength chart

    • DP460

      • FPL Etched Aluminium Shear Strength: 31 N/mm2 OR 4500 psi

      • Couldn’t find temp to % strength chart

    • Loctite - Hysol E‐120HP

      • room temp cure

      • Tensile strength of 41 N/mm^2

      • Aluminum abrasion and acid etched lap shear strength 33 N/mm^2 (4800 psi)

      • 100% strength even at 40 degrees Celsius

  • Tube and metal prep

    • Aluminum etching and Alodine coating to prevent corrosion and increase bond strength

      • West  System 860 Aluminum Etching Kit

      • DuPont Acid Etch and  Alodine solutions

    • Submerge Aluminum in etch solution, then submerge in non-diluted Alodine solution

  • Aluminum stock for insert

    • Check for appropriate lengths

      • Bond length increases linearly with bond strength

    • Gap 0.004 - 0.012 in for hot bonding

    • Gap 0.008 in for cold bonding

    • Carved aluminum, tapped for fitting a bearing insert

    • create shoulder only for grabbing in tensile test

    • In MIT paper, flashbreaker tape was used to add thickness at the end of the insert to create equal spacing and center insert.

  • Helicoil

    • Could avoid use if we use steel stock for the inserts

    • If we use a 1/4” - 28 End Rod

      • the bore hole will have to be #3 drill bit (0.213 inches)

      • tapped using 1/4" - 28 STI tap

      • Insert a 1/4" - 28 bolt Helicoil

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