Study on the SPCC and CFRTP Hybrid Joint Performance Produced with Additional Nylon-6 Interlayer by Ultrasonic Plastic Welding

Abstract

Due to the high degree of dissimilarity in physicochemical properties between metal and carbon fiber, it presents a tremendous challenge to join them directly. In this paper, cold rolled steel (SPCC) and carbon fiber reinforced thermoplastic (CFRTP) chopped sheet hybrid joints were produced with the addition of Nylon 6 (PA6) thermoplastic film as an intermediate layer by the ultrasonic plastic welding method. The effect of ultrasonic welding energy and preheating temperature on the hybrid joint microstructure and mechanical behavior was well investigated. The suitable joining parameters could obtain a strong joint by adding the PA6 film as an intermediate layer between the SPCC and bare carbon fibers. Microstructural analysis revealed that the interface joining condition between the PA6 film and the SPCC component is the primary reason for the joint strength. The crevices generated at the interface were eliminated when the preheating temperature arrived at 200 °C, and the joint strength thus significantly increased. The lap shear test results under quasi-static loading showed that the welding energy and preheating temperature synergistically affect the joint performances. At 240 °C, the joint strength value reached the maximum. Through the analysis of the microstructure morphology, mechanical performance, and the failure mechanism of the joint, the optimized joining process window for ultrasonic plastic welding of SPCC-CFRTP by adding an intermediate layer, was obtained.

A Review on the Recent Trends in Forming Composite Joints Using Spot Welding Variants

“…Figure 19 shows the weld morphology between CF/epoxy and Al with a PA6 film in between both sheets at a lower energy level. A similar observation was also reported in the joining of CFRP with steel [91].…”

Design of rose thorn biomimetic micro-protrusion for metals and CFRTP easily disassembled joining

“…Additionally, due to the concave shape of the inner contour of the micro-protrusion, this area will also act as an obstacle area to impede the upward movemen of the CFRTP. Moreover, during the welding process, the external energy input caused the resin on the CFRTP surface to melt, forming hydrogen bonding at the interface between metal and CFRTP [1,44]. This interaction increases shear and peel strength, resulting in a more durable and stable joint.…”

“…In the automotive industries, the pursuit of weight reduction has become a crucial objective due to its significant impact on vehicle performance, collision safety, fuel efficiency, and environmental sustainability [1,2]. By utilizing the integration of multi-material structures on vehicle bodies, such as carbon fiber reinforced thermoplastic (CFRTP) and metallic materials, substantial weight saving and high performances can be achieved [3].…”

Relaxation Model of the Relations between the Elastic Modulus and Thermal Expansivity of Thermosetting Polymers and FRPs

“…In structures such as gas and smoke chimneys and pipes for hot liquid transportation, different FRP joints in volume structures heating at temperatures higher than 40–50 °C influence the simultaneous non-linear changing of the modulus of elasticity (MoE) and the coefficient of thermal expansion (CTe). Thermal expansion (TE) and elasticity are the main properties that determine the deformability of the composite and the significant factors of polymers and FRP thermal stresses developing in real structures during exploitation [ 1 , 2 , 3 , 4 , 5 , 6 ]. Thus, the adequate relation between thermal expansibility and elasticity of materials fuels the decisions of many design tasks.…”