Finite element analysis of an inelastic interface in ultrasonic welded metal/fibre-reinforced polymer joints

Konchakova, Natalia; Balle, Frank; Barth, Franz Josef; Mueller, Ralf; Eifler, Dietmar; Steinmann, Paul

doi:10.1016/j.commatsci.2010.07.024

Cited by 30 publications

(14 citation statements)

References 10 publications

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“…80 Recent investigations reported that ultrasonic metal welding is very appropriate to join CFRP with lightweight Al alloys or Al-plated steel. 81 Balle et al 82 reported the feasibility of ultrasonic metal welding of Al alloy (AA5754) sheets of 1 mm thickness with composite CF-PA66 of 2 mm thickness in lap joint configuration and no damage in carbon fiber reinforcement was observed. Despite, several advantages of ultrasonic welding, the process is subjected to various disadvantages such as higher operating cost, material limitation, size limitations, and joint type limitations.…”

Section: Challenges In Joining Of Unequal Thickness Dissimilar Materials In Different Joint Configurations In Aircraft Applicationsmentioning

confidence: 99%

Challenges in joining of unequal thickness materials for aerospace applications: A review

Majeed

Mehta

Siddiquee

2020

Proceedings of the Institution of Mechanical Engineers, Part L:

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The increasing industrial demand to reduce structural weight, optimize structural strength, and high performance has led to the increasing use of tailors welded blanks. However, the joining of tailors welded blanks is an issue of concern to researchers owing to the difference in thickness between the materials in addition to the difference in physical and chemical properties in the case of dissimilar materials. These challenges in joining of tailors welded blanks are conquered by a recent solid phase joining process known as friction stir welding. This review work covers different methods of joining unequal thickness similar/dissimilar (or tailors welded blanks) aircraft materials in different joint configurations along with the challenges and failure modes encountered in these joining processes. From this article researchers and industrialists can take advantage and conquer relative limitations in order to meet the future challenges for joining of similar/dissimilar aircraft materials with unequal thickness

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Section: Challenges In Joining Of Unequal Thickness Dissimilar Materials In Different Joint Configurations In Aircraft Applicationsmentioning

confidence: 99%

Challenges in joining of unequal thickness materials for aerospace applications: A review

Majeed

Mehta

Siddiquee

2020

Proceedings of the Institution of Mechanical Engineers, Part L:

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“…The metal part of the specimen is treated in the computation model as a von Mises elastoplastic material with isotropic hardening . The total strain ϵ is split by

ϵ = {boldϵ}^{e} + {boldϵ}^{p}

into an elastic part ϵ e and a plastic part ϵ p .…”

Section: Deformation Behaviormentioning

confidence: 99%

Influence of the Shaping on Tribological Properties of PEEK‐Coated U‐Shaped Metal‐Profiles

et al. 2013

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Metal/fiber reinforced composite bearings consisting of a metallic substrate with a tribologically optimized polymer coating are produced with an additional layer of porous sintered bronze between polymer and metal to assure a high joint quality. With the aim to reduce cost and manufacturing complexity a thermal impact welding process was modified and applied to join a tribologically optimized PEEK to metallic substrates without the sintered bronze layer. [1] In the previous works, the thermal impact welding process was first optimized with steel substrates by varying process parameters such as substrate pretreatment, preheating temperature and cooling rate. The second step was to optimize the same process for aluminum substrates. With both substrate materials the optimized thermal impact welding process leads to an increase of tensile shear strength compared to the reference sample, PEEK-coated steel substrate with an additional sintered bronze layer. To prove the applicability of the process for bearings flat samples were produced by the new process and characterized tribologically. The results achieved with a plate on ring configuration showed that excellent wear and friction properties also can be achieved without the sintered bronze layer. [1] In this work, the PEEK-coated specimen are shaped to U-half-shells before testing them tribologically. The chosen shape leads to a tribological configuration that is similar to the situation in bearings and makes it possible to analyze the influence of the shaping on the properties. To gain more information on the state of the material after shaping the surfaces of sample have been analyzed. Numerical simulations have been performed to determine the stresses strains in the coating during shaping.

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“…The advantage of this type of solution is that there is no correlation between the surface roughness Ra and the shear strength of the joint. A similar technique is ultrasonic welding [14], which allows thermoplastic composites to be joined with aluminium alloys. In the work [15], the authors used a clinched metal-polymer type joint.…”

Section: Introductionmentioning

confidence: 99%

Experimental Study of Single-Lap, Hybrid Joints, Made of 3D Printed Polymer and Aluminium Adherends

et al. 2021

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This paper presents the results of an experimental study into single-lap joints. One part of the joint was made as a 3D printed polymer and had cylindrical tenons, while the other part was made of an aluminium flat bar having mortises whose diameter and distribution corresponded to the polymer tenons. In addition to the mechanical joint, a layer of double-sided VHB (Very High Bond) adhesive tape was also placed in the lap, thus creating a hybrid joint. In total, 80 specimens were made, which were divided into four groups: A—specimens with one tenon of different diameters, B—specimens with different number of tenons of the same diameter, C—specimens characterised by multi-stage operation and R—reference specimens, connected only by double-sided adhesive tape. The joints were subjected to uniaxial tensile tests. The force–displacement characteristics obtained and the energy required, up to the point of the failure of the joints, have been analysed in this paper. The four and six-stage joints designed can significantly increase the safety of the structures in which they will be used.

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Finite element analysis of an inelastic interface in ultrasonic welded metal/fibre-reinforced polymer joints

Cited by 30 publications

References 10 publications

Challenges in joining of unequal thickness materials for aerospace applications: A review

Challenges in joining of unequal thickness materials for aerospace applications: A review

Influence of the Shaping on Tribological Properties of PEEK‐Coated U‐Shaped Metal‐Profiles

Experimental Study of Single-Lap, Hybrid Joints, Made of 3D Printed Polymer and Aluminium Adherends

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