Ultrasonic Joining of Lightweight Alloy/Fiber‐Reinforced Polymer Hybrid Structures

Feistauer, Eduardo E.; Amancio‐Filho, Sergio T.

doi:10.1002/9781119429807.ch11

Cited by 3 publications

(1 citation statement)

References 31 publications

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“…Higher values of joining energy cause thermal-based defects like polymer degradation. 121 Higher welding energy results in excessive heat input, carbon fibre degradation, and detached aluminium debris, 61 which are some defects seen in USW. Al-CFRP, carbon fibres surround the aluminium particles by mechanical and intermolecular bonding.…”

Section: Microstructural Studiesmentioning

confidence: 99%

Review on the advancements and relevance of emerging joining techniques for aluminium to polymers/carbon fibre-reinforced polymer lightweight hybrid structures

Adarsh

Natarajan

2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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The demand for higher fuel efficiency and low fuel pollution rates leads to the development of lightweight hybrid structures. The predominant aim is to develop innovative light products with extreme versatility with bionomic and economic balance. Lightweight materials in the structures have successfully solved these problems in many industries, especially automobiles and aerospace. There is an emerging scope in producing automotive components by joining Al and Mg-based alloys with materials such as thermoplastics, ceramics and fibre-reinforced composites. Developing hybrid structures by employing metal–polymer joining is still a significant challenge. There are as many joining techniques available for joining metal with a polymer. Owing to certain drawbacks, some methods are ineffective, such as high processing time for adhesive bonding and mechanical fastening due to increased weight. The friction-based welding technique benefits hybrid joining due to its low heat-affected zone with less metallurgical damages. The study provides an overview of many emerging technologies for joining aluminium to thermoplastic/carbon fibre-reinforced polymer for lightweight structures. The paper compares different joint configurations and the effect of process variables on the microstructural and mechanical properties of hybrid joints. In addition, attempts are made to comprehend contemporary developments in the finite element simulation studies of hybrid structures. The paper also highlights recently developed strategies and gaps in areas where future studies might be focussed. Thus, the paper gives an overview of the advancements and relevance of the emerging joining technique for aluminium to polymers/carbon fibre-reinforced polymer hybrid structures.

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Section: Microstructural Studiesmentioning

confidence: 99%

Review on the advancements and relevance of emerging joining techniques for aluminium to polymers/carbon fibre-reinforced polymer lightweight hybrid structures

Adarsh

Natarajan

2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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An investigation of the ultrasonic joining process parameters effect on the mechanical properties of metal-composite hybrid joints

2020

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The ultrasonic joining process was recently introduced as an alternative concept to join through-the-thickness reinforced metal-composite hybrid structures. In this work, the investigation of joining process parameters effect on the joint mechanical performance of Ti-6Al-4V-glass-fiber-reinforced polyetherimide overlap joints was carried out by Box-Behnken design of experiments. The individual and combined effects of joining energy, sonotrode oscillation amplitude, and joining pressure on the ultimate lap shear force were elucidated by response surfaces method and analysis of variance. As a result of this study, a set of optimized joining parameters were obtained to produce joints with high ultimate lap shear force. The obtained reliable reduced model (R2 = 82%) displays a major influence of joining energy (25.3%) and sonotrode oscillation amplitude (21.2%) on the joint mechanical performance. Two-way interaction response surfaces were used to support strategies to optimize the maximum ultimate lap shear force. By comparing the optimized joint condition produced in this work with previously published results an improvement of 79% in ultimate lap shear force was attained, thereby, proving the potential of the proposed process optimization procedure.

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Fiber orientation in continuous fiber-reinforced thermoplastics/metal hybrid joining via multi-pin arrays

Popp

Busch

Hausotte

et al. 2023

Science and Engineering of Composite Materials

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Continuous fiber-reinforced thermoplastics (CFRTs) can in combination with high-strength metals offer characteristics that cannot be achieved with mono-material parts. One possible example is the combination of locally high-temperature resistance in the metal component with superior weight-related mechanical properties due to the CFRT component. This approach requires a reliable and durable joining technology, which considers the material-specific properties and allows to exploit the full potential of CFRT/metal hybrid parts. A promising approach in the field of CFRT/metal joining is the use of metallic pins, which can be embedded in the locally heated CFRT component to create a form-fitting joint. In the current state of the art, primarily single-pins are investigated and characterized: especially the distinct fiber orientation in the direct pin pressing process is only described for single-pin joints. Behind this background, the present study aims at creating an understanding of the fiber orientation mechanism for multi-pin arrays. Therefore, in the scope of this study, unidirectional reinforced glass fiber/polypropylene samples are joined via direct pin pressing and infrared heating with different 1D and 2D multi-pins arrays with different pin-diameters, spacing and pin distributions. The resulting joint morphology is consequently analyzed using micro-computer-tomography. Based on the performed investigations, a model for the fiber displacement mechanism is proposed, and the first recommendations for the design of fiber-friendly multi-pin joints with unidirectional reinforcements are given. It showed that especially pin-spacing in fiber orientation in dependency of the pin diameter is critical for a fully reconsolidated joint quality, and it is suggested that a pin-offset in the fiber direction is beneficial for a fiber-friendly joining process.

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Ultrasonic Joining of Lightweight Alloy/Fiber‐Reinforced Polymer Hybrid Structures

Cited by 3 publications

References 31 publications

Review on the advancements and relevance of emerging joining techniques for aluminium to polymers/carbon fibre-reinforced polymer lightweight hybrid structures

Review on the advancements and relevance of emerging joining techniques for aluminium to polymers/carbon fibre-reinforced polymer lightweight hybrid structures

An investigation of the ultrasonic joining process parameters effect on the mechanical properties of metal-composite hybrid joints

Fiber orientation in continuous fiber-reinforced thermoplastics/metal hybrid joining via multi-pin arrays

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