New Joining Technology for Optimized Metal/Composite Assemblies

Abstract

The development of a new joining technology, which is used to manufacture high strength hybrid constructions with thermoplastic composites (FRP) and metals, is introduced. Similar to natural regulation effects at trees, fibers around the FRP joint become aligned along the lines of force and will not be destroyed by the joining process. This is achieved by the local utilization of the specific plastic flow properties of the FRT and metal component. Compared with usual joining methods—such as flow drill screws, blind and self-piercing rivets—noticeably higher tensile properties can be realized through the novel process management. The load-bearing capability increasing effect could be proved on hybrid joints with hot-dip galvanized steel HX420LAD and orthotropic glass—as well as carbon—fiber reinforced plastics. The results, which were determined in tensile-shear and cross-shear tests according to DIN EN ISO 14273 and DIN EN ISO 14272, are compared with holding loads of established joining techniques with similar joining point diameter and material combinations.

Influence of cathodic dip painting on the mechanical strength of material-adapted composite/metal joints

“…After numerous investigations on parameter studies, design rules and material combinations [4][5][6], the novel joining technique has to be qualified for the use in conventional automotive manufacturing processes. Since all car body structures are passing through a conventional automotive process chain, the joining techniques need to be resistant to all temperature loads and chemicals, applied during the production processes, e.g., in vehicle lacquering.…”

Clinching of Thermoplastic Composites and Metals—A Comparison of Three Novel Joining Technologies

“…The phenomena occurring during the forming of the heated TPC as well, as the joint formation and performance for the three technologies, are compared in the following. [8], (b) Friction assisted Clinching [9], (c) Thermoclinching [16], (d) hole [6]/hole free [11,12] clinching, (e) Flow Drill Joining [15], (f) Two-Step Clinching [13], (g) Hotclinching [17], (h) Preheated Clinching [14], (i) Insert Clinching.…”

Simulation‐aided development of a robust thermoclinching joining process for hybrid structures with textile reinforced thermoplastic composites and metallic components

“…Considering that continuous reinforced thermoplastic composites provide a limited plastic deformation range, established joining technologies are only partly transferable. An adapted joining process to produce such hybrid connections is making use of the plastic flow properties of the metal component [7]. Thereby the metal sheet is thermomechanically formed through the composite by a rotating pin and then embossed into an undercut by an additional punch.…”