Laser joining of CFRTP to metal: A review on welding parameters, joint enhancement, and numerical simulation

For weight reduction, multi-material designs comprising metal and fiber-reinforced plastic (FRP) components in vehicle body structures have been increasingly used. However, the commonly used resistance spot welding (RSW) technology for car body assembly cannot be employed to join sheet metal and FRPs, limiting the use of FRPs. To solve this problem, a novel resistance insert spot welding (RISW) technique was developed in this work for RSW of steel parts and FRP structure parts made by injection molding. Small inserts were developed by using finite element method and experiments that may be welded to different micro-alloyed and dual-phase sheet steels using the projection welding method. The usual flange width of original equipment manufacturers could be kept unchanged. Using the developed insert and welding parameters, the maximum temperature in the FRPs surrounding the inserts was limited to 255 °C, minimizing the damage to polyamide 6 (PA6) material (with 40 wt% glass fiber). A weldability range between 2.5 and 7 kA could be achieved. The joining strength of RISW between a micro-alloyed HC340 steel in 0.75 mm and 1.5 mm thickness and a 2.5 mm/3.0 mm PA6-GF40 material is 20 to 80% higher than self-piercing riveting (SPR). For high-speed loading, RISW strength increases by 39 to 56% further. Finally, RISW was successfully applied to an FRP–steel roof-frame sub-assembly that consists of 19 simultaneously integrated inserts, achieving 10% weight reduction.

A new resistance insert spot welding method for injection-molded FRP–steel component

Xu,

Fang

2024

Influence of pre-treatment with non-thermal atmospheric pressure plasma on bond strength of TP340 titanium-PEEK direct bonding

Takenaka,

Nakamoto,

Koyari

et al. 2024

Direct bonding of a TP340 titanium to PEEK by hot pressing via pre-treatment of non-thermal atmospheric pressure plasma jet has been demonstrated. The plasma irradiation effect on the bonding surface on the bond strength after hot pressing was investigated. The tensile shear strength of TP340-PEEK joined by hot pressing after plasma pre-treatment was measured by comparing specimens bonded using conventional hot pressing and those bonded using adhesives. The plasma treatment to the TP340 side resulted in the formation of TiO2, which is chemically fed to oxide formation due to the irradiation of oxygen radicals generated by the plasma, resulting in a bond strength of less than 1 MPa, similar to the bond strength of the untreated specimens. The plasma irradiation effect on the PEEK side on the bond strength of TP340-PEEK bonded samples was also investigated. The bonding strength was increased by plasma irradiation to PEEK. As the plasma irradiation time was increased, the bonding strength gradually increased to 9.2 MPa, which is about 19 times higher than the bonding strength without plasma irradiation. These results suggest that oxygen radicals in the atmospheric pressure RF plasma jet produced oxygen-containing surface functional groups on the PEEK surface, which increased the strength of the TP340-PEEK direct joining.

Gap bridging in laser welding of EN AW 5083 with different joint configurations via beam oscillation and filler wire

Yetil,

Colombo,

Ayan

et al. 2024

The extended use of laser welding in the industry requires a less sensitive process in terms of geometrical tolerances of the joint edges. As the industrial availability of laser systems increases, the demand to use laser welding technology possibly with parts coming from less precise production steps is increasing. Gap formation is often caused by the edge quality of the parts coming from previous manufacturing steps such as sheet forming. Al alloy sheets deformed to box-shaped 3D forms often require welded joints on the edges in lap, but, and corner joint configurations. These joints are hard to carry out by laser welding due to the large gap formation caused by the tolerances of the deformation processes involved. Laser welding of Al alloys is already challenging in the absence of gap formation, while these joint configurations have been not feasible with a stationary beam due to incomplete fusion and defect formation. Laser welding with beam oscillation and wire feeding can improve the weldability of these joints. The oscillating motion of the high-intensity beam can achieve a deep weld together with a wider seam. Combined with wire feeding, the process can close gaps in the butt, lap, and corner joint configurations. On the other hand, the added oscillation and wire-related parameters require extending the experimental space, which requires a methodological study to identify feasible conditions. Accordingly, this work proposes a methodological approach to identify and set laser welding process parameters with beam oscillation and wire feeding for an EN AW 5083. Process parameters were initially studied using a simple analytical model that depicts the beam trajectory. Bead-on-plate tests were conducted to assess beam size, power, and weld speed ranges. Lap, butt, and corner joint conditions with a 0.5-mm gap were welded with high quality by manipulating the laser power, oscillation amplitude, and wire feed rate. The results show that welding speeds could be maintained as high as 55 mm/s with complete filling of gaps of up to 0.5 mm, eliminating the surface undercuts and achieving weld widths in the order of 2.5 mm. Moreover the results show the possibility control the depth of the welds from 3 mm to full-penetration conditions.