Achieving a strong polypropylene/aluminum alloy friction spot joint via a surface laser processing pretreatment

Han, Shuai; Wu, L.H.; Jiang, Chengbao; Li, N.; Jia, Chunmei; Xue, P.; Zhang, H.; Zhao, H.B.; Ni, D.R.; Bolyu, Xiao; Ma, Zhijun

doi:10.1016/j.jmst.2020.02.035

Cited by 40 publications

(8 citation statements)

References 31 publications

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“…Less energy transferred into the metal corresponded to lower roughness parameters of the micro-structurized aluminum surface. Very similar relationships between surface roughness and laser-scanning parameters for the Al alloy 5182 were investigated by Han et al [28]. They used a pulse-mode working laser, at a frequency of 100 kHz, a nominal power 100 W and a scan speed of 700 mm/min.…”

Section: Resultsmentioning

confidence: 76%

Polyamide 6-Aluminum Assembly Enhanced by Laser Microstructuring

Bula¹,

Korzeniewski²

2022

Polymers

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The presented work’s aim is the application of low-power laser treatment for the enhancement of interfacial micromechanical adhesion between polyamide 6 (filled with glass fiber) and aluminum. A fiber laser beam was used to prepare micro-patterns on aluminum sheets. The micro-structuring was conducted in the regime of 50, 100, 200 and 300 mm/s laser beam speeds, for both sides. The joining process was realized in an injection molding process. Metallic inserts were surface engraved and overmolded in one-side and two-side configurations. A lap shear test was used to examine the strength of the joints. Engraved metallic surfaces and adequate imprints on polyamide side were checked by optical microscope with motorized stages, and roughness parameters were also determined. Microscopic observations made it possible to describe the grooves’ shape and to conclude that a huge recast melt was formed when the lowest laser beam speed was applied; thus, the roughness parameter Ra reached the highest value of 16.8 μm (compared to 3.5 μm obtained for the fastest laser speed). The maximum shear force was detected for a sample prepared with the lowest scanning speed (one-sides joints), and it was 883 N, while for two-sided joints, the ultimate force was 1410 N (for a scanning speed of 200 mm/s).

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Section: Resultsmentioning

confidence: 76%

Polyamide 6-Aluminum Assembly Enhanced by Laser Microstructuring

Bula¹,

Korzeniewski²

2022

Polymers

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“…The surface pretreatment has a considerable impact on the subsequent mechanical strength of the bond and the occurring adhesion mechanisms in the joint. Mechanical processes, such as grinding [6], sandblasting [7], or pre-drilling [8], as well as chemical [9] and optical [5,[10][11][12] methods were studied as methods for the pretreatment. In this context, laser-based methods demonstrated both economic and technological advantages [5,12].…”

Section: State Of the Art 21 Friction Press Joining For Plastic-metmentioning

confidence: 99%

A Holistic, Model-Predictive Process Control for Friction Stir Welding Processes Including a 1D FDM Multi-Layer Temperature Distribution Model

Meyer

Fuderer

Zaeh

2021

Metals

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Friction press joining is an innovative joining process for bonding plastics and metals without additives in an overlap configuration. This paper presents for the first time a model-based approach for designing a multi-variable model predictive control (MPC) for friction press joining. For system modeling, a differential equation based on the heat flows was proposed and modeled as a torque-dependent function. With this model, it is possible to consider cross-effects between the axial force and the friction zone temperature. With this theoretical approach, adaptive model-predictive process control was implemented and validated for different material combinations (EN AW-6082-T6; EN AW-2024-T3; PE-HD; PA6-GF30; PPS-CF). It could be shown that the MPC has excellent control accuracy even when model uncertainties are introduced. Based on these findings, a 1D Finite Differential Method multi-layer model was developed to calculate the temperature in the plastic component, which is not measurable in situ (r = 0.93). These investigations demonstrate the high potential of the multi-variable MPC for plastic-metal direct joining.

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“…Due to its lower weight, they are also energy-saving, important for the environment. Various types and designing of such elements were described in publications where the most demanded bi-materials joints are formed by the mechanical clinching technique [1,2], friction spot/lap welding [3][4][5], laser assisted joining [6], common laser pretreatment and friction spot joining [7], ultrasonic joining [8], powder metallurgy assisted with laser irradiation [9], additive manufacturing [10], fused deposition modeling etc. The materials selected for both laminate partners should reveal characteristic properties like defined compatibility with environmental conditions, thermal conductivity or resistance, tendency of vibration damping of the construction and others.…”

Section: Introductionmentioning

confidence: 99%

Experimental and numerical investigation of metal-polymer riveted joints

Roszak¹,

Bula²,

Sagradov³

et al. 2022

Mater. Res. Express

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This paper presents the modeling and analysis of the joints of metal inserts with polyamide 6 using the injection technique. Based on the conducted experiments, modeling and numerical calculations of joints were carried out for various joint configurations. Metal parts, made of steel grade DC 04, are mechanically locked with polyamide 6 (PA6) with rivets. The mechanical connection with rivets of both elements was achieved by filling the holes in the metal parts in the injection process. As part of the work, mechanical-clamp connections made of steel / PA6 were mechanically tested in a single-axis joint tensile test using appropriate tabs. The main goal was to study and numerically analyze the number of rivets and their location on the metal plate for the strength of the connector. An important element of the work was the modeling process of both the PA6 material behavior and the joint itself. As part of the experimental research, the rivet deformation was also observed using computer thermography with the use of an IR camera. The tests and simulation showed that for the sample, the polymer-metal connected with less than three rivets was destroyed by shear. On the other hand, when the polymer-metal junction was made of three rivets, the jamming mechanism was mainly related to damage to the polymer part. For these joints, the maximum values of the breaking force of the joint were obtained in uniaxial tensile and shear tests where three rivets were used. Similar values were obtained during the numerical calculations performed with the use of Abaqus software.

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Achieving a strong polypropylene/aluminum alloy friction spot joint via a surface laser processing pretreatment

Cited by 40 publications

References 31 publications

Polyamide 6-Aluminum Assembly Enhanced by Laser Microstructuring

Polyamide 6-Aluminum Assembly Enhanced by Laser Microstructuring

A Holistic, Model-Predictive Process Control for Friction Stir Welding Processes Including a 1D FDM Multi-Layer Temperature Distribution Model

Experimental and numerical investigation of metal-polymer riveted joints

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