An alternative additive manufacturing-based joining method to make Metal/Polymer hybrid structures

Ozlati, Ashkaan; Movahedi, M.; Tamizi, M.; Tartifzadeh, Z.; Alipour, Siamak

doi:10.1016/j.jmapro.2019.07.002

Cited by 28 publications

(16 citation statements)

References 33 publications

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“…Thus, a possible explanation of the localization of polymer breakage may be related to the existence of evident cross-section changes around the rivet (see Figure 4b,c). Ozlati et al [25] studied bimaterial joints realized with only one rivet formed by FDM, with various diameters. On the basis of the tensile-shear test, it was found that all samples failed at the joint area, which meant that only shearing of the rivets had occurred.…”

Section: Lap-shear Test Resultsmentioning

confidence: 99%

“…Nowadays, the joining technique of a polymer to metals using rapid prototyping methods should also be considered. Ozlati et al [25] ascribed fused deposition modeling (FDM), applied to the production of a lap connection of polypropylene (PP) fibers with Al-Mg alloy sheets placed between the PP fibers and as mechanical lock between the base aluminum sheet and the additive component. The impact of the area of the joint interface and of the primary heating of the components (by 20, 50, and 90 • C) on mechanical values was studied.…”

Section: Introductionmentioning

confidence: 99%

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Deformation Mechanism in Mechanically Coupled Polymer–Metal Hybrid Joints

et al. 2020

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In this, work, metal inserts were joined with polyamide 6 by using the injection-molding technique. The metal parts, made of steel grade DC 04, were mechanically interlocked with polyamide 6 (PA6) by rivets as a mechanical connection between both components in the form of s polymer filling the holes in the metallic parts. The mechanical-interlocking joints made of steel/PA6 were mechanically tested in a tensile-lap-shear test. The damage behavior of the joined materials in relation to rivet number and position on the metal plate was studied. The observation of rivet deformation was also conducted by infrared IR thermography. The study showed that, for polymer–metal joined samples with fewer than three rivets, the destruction of rivets by shearing meant sample damage. On the other hand, when the polymer–metal joint was made with three or four rivets, the disruption mechanism was mostly related to the polymer part breaking. The maximal values of the joint’s failure force under tensile-shear tests were achieved for samples where three rivets were used. Moreover, strong correlation was found between the surface temperature of the samples and their maximal force during the tensile-lap-shear test.

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Section: Lap-shear Test Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Deformation Mechanism in Mechanically Coupled Polymer–Metal Hybrid Joints

et al. 2020

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“…The rotating probe stirs against the metal surface leading to the formation of hooks that fastens the two components [9,10,41], as depicted in Figure 13a. A variant of the process that involves the direct deposition of polymeric material through fused deposition modeling (FDM) has been recently developed to avoid the use of a pre-prepared stud [8]. In fused deposition modeling, the through-hole produced on the metal joining partner is filled by the molten material exiting from an extrusion head of an FDM machine.…”

Section: Friction Stir Lap Weldingmentioning

confidence: 99%

A State-of-the-Art Review on Advanced Joining Processes for Metal-Composite and Metal-Polymer Hybrid Structures

et al. 2021

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Multi-materials of metal-polymer and metal-composite hybrid structures (MMHSs) are highly demanded in several fields including land, air and sea transportation, infrastructure construction, and healthcare. The adoption of MMHSs in transportation industries represents a pivotal opportunity to reduce the product’s weight without compromising structural performance. This enables a dramatic reduction in fuel consumption for vehicles driven by internal combustion engines as well as an increase in fuel efficiency for electric vehicles. The main challenge for manufacturing MMHSs lies in the lack of robust joining solutions. Conventional joining processes, e.g., mechanical fastening and adhesive bonding involve several issues. Several emerging technologies have been developed for MMHSs’ manufacturing. Different from recently published review articles where the focus is only on specific categories of joining processes, this review is aimed at providing a broader and systematic view of the emerging opportunities for hybrid thin-walled structure manufacturing. The present review paper discusses the main limitations of conventional joining processes and describes the joining mechanisms, the main differences, advantages, and limitations of new joining processes. Three reference clusters were identified: fast mechanical joining processes, thermomechanical interlocking processes, and thermomechanical joining processes. This new classification is aimed at providing a compass to better orient within the broad horizon of new joining processes for MMHSs with an outlook for future trends.

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“…Due to its lower weight, they are also energy-saving, important for the environment. Various types and designing of such elements were described in publications where the most demanded bi-materials joints are formed by the mechanical clinching technique [1,2], friction spot/lap welding [3][4][5], laser assisted joining [6], common laser pretreatment and friction spot joining [7], ultrasonic joining [8], powder metallurgy assisted with laser irradiation [9], additive manufacturing [10], fused deposition modeling etc. The materials selected for both laminate partners should reveal characteristic properties like defined compatibility with environmental conditions, thermal conductivity or resistance, tendency of vibration damping of the construction and others.…”

Section: Introductionmentioning

confidence: 99%

Experimental and numerical investigation of metal-polymer riveted joints

Roszak¹,

Bula²,

Sagradov³

et al. 2022

Mater. Res. Express

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This paper presents the modeling and analysis of the joints of metal inserts with polyamide 6 using the injection technique. Based on the conducted experiments, modeling and numerical calculations of joints were carried out for various joint configurations. Metal parts, made of steel grade DC 04, are mechanically locked with polyamide 6 (PA6) with rivets. The mechanical connection with rivets of both elements was achieved by filling the holes in the metal parts in the injection process. As part of the work, mechanical-clamp connections made of steel / PA6 were mechanically tested in a single-axis joint tensile test using appropriate tabs. The main goal was to study and numerically analyze the number of rivets and their location on the metal plate for the strength of the connector. An important element of the work was the modeling process of both the PA6 material behavior and the joint itself. As part of the experimental research, the rivet deformation was also observed using computer thermography with the use of an IR camera. The tests and simulation showed that for the sample, the polymer-metal connected with less than three rivets was destroyed by shear. On the other hand, when the polymer-metal junction was made of three rivets, the jamming mechanism was mainly related to damage to the polymer part. For these joints, the maximum values of the breaking force of the joint were obtained in uniaxial tensile and shear tests where three rivets were used. Similar values were obtained during the numerical calculations performed with the use of Abaqus software.

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An alternative additive manufacturing-based joining method to make Metal/Polymer hybrid structures

Cited by 28 publications

References 33 publications

Deformation Mechanism in Mechanically Coupled Polymer–Metal Hybrid Joints

Deformation Mechanism in Mechanically Coupled Polymer–Metal Hybrid Joints

A State-of-the-Art Review on Advanced Joining Processes for Metal-Composite and Metal-Polymer Hybrid Structures

Experimental and numerical investigation of metal-polymer riveted joints

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