Ultrasonic welding of metal to fiber-reinforced thermoplastic composites: A review

Liu, Zeguang; Li, Yang; Liu, Zhiwei; Yang, Yuanduo; Li, Yiang; Zhang, Luo

doi:10.1016/j.jmapro.2022.12.001

Cited by 27 publications

(6 citation statements)

References 58 publications

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“…The mainstream method of metal/CFRTP welding is first to pre-treat the metal surface, such as by manufacturing macro-or microstructures on the metal surface. These structures help to increase the effective connection area and improve the mechanical interlocking between metal and CFRTP, as reported by Liu et al [5]. Afterward, welding, such as laser welding, friction stir welding or hot-press welding, will be used to heat the metal sheet above the melting point of CFRTP.…”

Section: Introductionmentioning

confidence: 92%

Process Characterizations of Ultrasonic Extruded Weld-Riveting of AZ31B Magnesium Alloy to Carbon Fiber-Reinforced PA66

Liu,

Lu,

Yang

et al. 2024

Polymers

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Traditional metal–plastic dissimilar welding methods directly heat the metal workpiece, which may cause potential thermal damage to the metal workpiece. Ultrasonic extruded weld-riveting (UEWR) is a relatively new method for dissimilar joining of carbon fiber-reinforced thermoplastic (CFRTP) and metal. In this method, the CFRTP workpiece is melted using the ultrasonic effect and is squeezed into prefabricated holes in the metal workpiece to form a rivet structure. In this method, the metal workpiece is not directly heated, and potential high-temperature losses can be avoided. This paper investigates the process characterizations of UERW of AZ31B magnesium alloy to carbon fiber-reinforced PA66. The process parameters are optimized by the Taguchi method. The joint formation process is analyzed based on the fiber distribution in the cross-sections of joints. The effects of welding parameters on the joint microstructure and fracture surface morphology are discussed. The results show that a stepped amplitude strategy (40 μm amplitude in the first stage and 56 μm amplitude in the second stage) could balance the joint strength and joint appearance. Insufficient (welding energy < 2600 J or amplitude-A < 50%) or excessive (welding energy > 2800 J or amplitude-A > 50%) welding parameters lead to the formation of porous defects. Three fracture modes are identified according to the fracture surface analysis. The maximum tensile shear strength of joints at the optimal parameters is about 56.5 ± 6.2 MPa.

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Section: Introductionmentioning

confidence: 92%

Process Characterizations of Ultrasonic Extruded Weld-Riveting of AZ31B Magnesium Alloy to Carbon Fiber-Reinforced PA66

Liu,

Lu,

Yang

et al. 2024

Polymers

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“…Various joining technologies, including mechanical fastening, laser welding, friction stir welding, ultrasonic joining, and adhesive joining have been implemented to join CFRTP and metals [9][10][11][12][13][14][15]. These techniques have their benefits in particular application fields, but each has inherent limitations and drawbacks [16,17]. Mechanical fastening can extend joining time due to increased manufacturing complexity and may damage carbon fibers, as well as the occurrence of stress concentration near drilling zone [12].…”

Section: Introductionmentioning

confidence: 99%

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

Wang,

Yasuda,

Nishikawa

2024

Eng. Res. Express

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This study focuses on the joining techniques for metals and carbon fiber reinforced thermoplastic (CFRTP) to address the pursuit of lightweight vehicles and high recycling efficiency. The innovative concept of “easy-disassembly joining” is introduced for the first time, aiming for robust joint strength and efficient disassembly/recycling of end-of-life vehicles. Inspired by rose thorn morphology and natural performances, bionic micro-protrusions are explored as intermediate structures to facilitate the easy disassembly joining between metals and CFRTP. The primary focus of the study revolves around the design strategy of micro-protrusions inspired by rose thorns. The objective is to identify the most effective micro-protrusion shapes by understanding the interplay of its geometrical parameters, including base shape, apex position, profile curvature, and stress distribution under diverse loads. Utilizing static stress numerical simulations, the study conclusively identifies an elliptical base shape with the apex positioned slightly above the right edge of the structure. The outer profile adopts a circular arc, and the inner profile follows a conical curve. This configuration effectively mitigates stress concentration at the bottom, which interfaces with the metal substrate and the smaller areas around the apex. This research introduces an innovative concept for metal-CFRTP joining and applies bionic principles in engineering solutions. By promoting lightweight and sustainable structures through enhanced disassembly efficiency, it contributes to groundbreaking advancements in the field.

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“…Joining dissimilar materials is often challenging due to the differences in chemical, mechanical, thermal, or electrical properties. As a low-cost and environment-friendly technique, ultrasonic welding is extensively used to join dissimilar materials, such as aluminum/steel [3][4][5], aluminum/magnesium [6,7], aluminum/titanium [8], and metal/fiber-reinforced polymers [9] in automotive, aviation, and aerospace applications. As ultrasonic welding provides advantages in joining multiple thin sheets of highly conductive materials, it serves as one of the major joining techniques in current automotive lithium-ion-based battery manufacturing [10][11][12].…”

Section: Introductionmentioning

confidence: 99%

Development of a High-Frequency Test System to Study the Wear of Ultrasonic Welding Tools

Li,

Rienks,

Balle

2023

Metals

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In current automotive lithium-ion battery manufacturing, Ultrasonic Metal Welding (USMW) is one of the major joining techniques due to its advantages in welding multiple thin sheets of highly conductive materials. The sonotrode, serving as the welding tool, transmits high-frequency oscillation to the joining parts. Due to the high frequency of thermal-mechanical loading, the knurl pattern on the sonotrode wears with an increasing number of welds, which significantly influences the welding process, resulting in poor joint quality. In this study, a high-frequency test system was developed to investigate the wear mechanisms of the sonotrode. Based on the comparable relative motion to the welding process, the thermal-mechanical loadings on the contact area were analyzed. As the oscillation amplitude of the sonotrode increased, the estimated frictional force between the sonotrode and the copper counter body remained constant, while an increase in the sliding distance was observed in the contact area. Temperature development showed a strong correlation with mechanical loading. A first approach of continuous testing was performed but was limited due to the failure of the copper counter body under ultrasonic stimulation.

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Ultrasonic welding of metal to fiber-reinforced thermoplastic composites: A review

Cited by 27 publications

References 58 publications

Process Characterizations of Ultrasonic Extruded Weld-Riveting of AZ31B Magnesium Alloy to Carbon Fiber-Reinforced PA66

Process Characterizations of Ultrasonic Extruded Weld-Riveting of AZ31B Magnesium Alloy to Carbon Fiber-Reinforced PA66

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

Development of a High-Frequency Test System to Study the Wear of Ultrasonic Welding Tools

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