3D X-ray Microscopy of Ultrasonically Welded Aluminum/Fiber-Reinforced Polymer Hybrid Joints

Abstract

Ultrasonically welded hybrid aluminum/fiber-reinforced PEEK joints were analyzed non-destructively with an X-ray microscope. The potential and limitations of the technology as a non-destructive testing method were investigated. For a quantitative evaluation, joints with suitable and unsuitable parameters were compared. For a further comparison, geometric modifications of the joining partners were made, and the influence on the structure and process variation of the resulting hybrid joints was examined on a microscopic level. By using a tool for 3D segmentation of the composition of the joining zone, quantitative information on volume-specific proportions could be obtained and compared in relation to each other.

A review of quality monitoring for ultrasonic metal welding

“…In addition, it is difficult to use this test method which is sensitive in complex environment. Microscopic imaging of aluminium/fibre-reinforced polymer composite ultrasonically welded joints using threedimensional X-ray microscopy (XRM) was conducted by Staab et al 85 Compared with TEM and SEM, XRM can use mathematical algorithm to create a virtual 3D model of the specimen without destroying it and can obtain any virtual sample cross-section for non-destructive testing of weld joints, as shown in Figure 17. In addition, they quantified the quality of the weld by comparing different algorithms and derived the effect of welding parameters on porosity.…”

“…Figure 17. The images of the X-ray microscopy at the weld: (a) A-A cut, (b) B-B cut along the joining area of a specimen welded with non-suitable parameters and (c) overview of the specimen 85. …”

Optimization of Ultrasonic Welding Process Parameters to Enhance Weld Strength of 3C Power Cases Using a Design of Experiments Approach

“…The maximum temperature increased with multiwalled carbon nanotubes and film thickness. Staab et al [15] investigated the potential and limitations of the technology as a non-destructive testing method. In addition, quantitative information on volume-specific proportions could be obtained and compared in relation to each other using a tool for 3D segmentation of the composition of the joining zone.…”

Fatigue and fracture of ultrasonically welded aluminum alloys to carbon fiber reinforced thermoplastics

“…By introducing a mechanical oscillation into the joining zone, heat is initially generated in the interface via friction between the joining partners. 19 For the designated material combination, this leads to a melting of the thermoplastic layer in the welding interface. Combined with a superimposed welding force, plastic deformation of the metallic joining partner is induced, resulting in a mechanical interlocking between the metal and the uppermost fiber layer.…”

“…The advantages of the process are its robustness, short process times of only a few seconds, a sustainable low energy consumption, and the possibility of high automation. By introducing a mechanical oscillation into the joining zone, heat is initially generated in the interface via friction between the joining partners 19 . For the designated material combination, this leads to a melting of the thermoplastic layer in the welding interface.…”