An Electrical Resistance Joining Technology for Carbon Fiber-Reinforced Polyphenylene Sulfide Composites

Okayasu, Mitsuhiro; Kubota, Tomohumi

doi:10.1007/s11665-020-04764-3

Cited by 3 publications

(1 citation statement)

References 25 publications

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“…Principally, in these techniques, the polymer matrix partially remelts that produces a joint with a metallic member after consolidation ( Ref 12). Depending on the heat source to remelt the polymer matrix, several processes have been used including induction welding (Ref 13), resistance spot welding (Ref 14,15), ultrasonic welding (Ref 16,17) and laser welding ( Ref 18,19). Friction stir welding-based processes have also attracted growing interest due to the energy efficiency and environmental friendliness ( Ref 20).…”

Section: Introductionmentioning

confidence: 99%

A New Design for Friction Stir Spot Joining of Al Alloys and Carbon Fiber-Reinforced Composites

Bolouri

Fotouhi

Moseley

2020

J. of Materi Eng and Perform

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Friction stir spot welding (FSSW) has been recently developed to join dissimilar materials. However, the traditional requirement for a rotating tool consists of a pin and shoulder in FSSW leads to a complex joining process and unpredictable defects. In this study, a new static-shoulder design in FSSW was proposed and developed to join Al alloys to carbon fiber-reinforced polymer (CFRP) composites. The main joining parameters, including pin rotational speed, pin feed rate and pin plunge depth, were varied to investigate their effects on the joining temperature, materials interaction and the strength of joints. The pin rotational speed had the largest influence on the joining temperature. Lap shear tensile testing was conducted to evaluate the performance of the joints. The joints exhibited the ultimate lap shear force from 230 to 260 N. A brittle fracture occurred with the displacement-at-fracture load of 0.35-0.41 mm. Cross-sectional images revealed the creation of undulations on the surface of Al alloys in the joining zone. The undulations created a macro-mechanical interlocking bonding between the materials, which determined the performance of the joints. For a flat pin, by increasing the plunge depth from 1.25 to 1.30 mm, the undulation size increased from 0.21 to 0.26 mm, which can enhance the macro-mechanical interlocking bonding between Al alloys and CFRP and accordingly increased the ultimate shear force of the joints from 230 to 241 N. Use of a fluted pin significantly influenced the flow of the plasticized Al alloy which created pronounced undulations and large Al alloy spikes of 0.46 mm. These features seemed to establish an efficient macro-mechanical interlocking bonding, which resulted in a noticeable improvement in the performance of the joint. For a plunge depth of 1.30 mm, the ultimate shear force increased to 261 N using the fluted pin.

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Section: Introductionmentioning

confidence: 99%

A New Design for Friction Stir Spot Joining of Al Alloys and Carbon Fiber-Reinforced Composites

Bolouri

Fotouhi

Moseley

2020

J. of Materi Eng and Perform

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Response Surface Methodology Optimization of Resistance Welding Process for Unidirectional Carbon Fiber/PPS Composites

Yu,

Qing,

Lin

et al. 2024

Materials

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The use of thermoplastic composites (TPCs) as one of the lightweight solutions will inevitably encounter problems in connection. Resistance welding has the characteristics of high strength, simplicity, and high reliability, and is considered a very potential hot-melt connection technology. The resistance welding technology of unidirectional carbon fiber-reinforced polyphenylene sulfide composites (UCF/PPS) was systematically studied. The experimental results show that the 100-mesh brass mesh has the best resin wetting effect and heating efficiency, and the PPS/oxidized 100-mesh brass mesh composite resistance element (Ox-RE/PPS) has the highest welding strength. The welding failure mode changes from interface failure and RE failure to interlayer structure damage and fiber fracture. The single-factor experimental results show that the maximum welding strength is reached at 310 °C, 1.15 MPa, and 120 kW/m2. According to the conclusion of the single-factor experiment, the Box–Behnken method was further used to design a three-factor, three-level experiment, and a quadratic regression model was established according to the test results. The results of variance analysis, fitting curve analysis, and perturbation plot analysis proved that the model had high fitting and prediction abilities. From the 3D surface diagram analysis, the influence of power density is the largest, and the interaction between welding temperature and power density is the most significant. Combined with the analysis of Design Expert 13 software, the optimal range of process parameters was obtained as follows: welding temperature 313–314 °C, welding pressure 1.04–1.2 MPa, and power density 124–128 kW/m2. The average strength of resistance welding joints prepared in the optimal range of process parameters was 13.58 MPa.

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Advances in Resistance Welding of Fiber-Reinforced Thermoplastics

Geng,

Yu,

Wang

et al. 2024

Materials

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Fiber-reinforced thermoplastics (FRTPs) have become a new generation of lightweight materials due to their superior mechanical properties, good weldability and environmental resistance, potential for recycling, etc. The market for FRTPs is expected to grow at a compound annual growth rate (CAGR) of 7.8% from 2022 to 2030. Many researchers have been trying to solve the problems in their processing and joining process, and gradually expand their application. Resistance welding is one of the most suitable techniques to join FRTPs. This paper summarizes the research progress of FRTP resistance welding in terms of the basic process of FRTP resistance welding, factors affecting joint performance, joint failure behavior, numerical simulation, weld quality control, and resistance welding of thermoplastic/thermoset composites. The objective of this paper is to provide a deeper insight into the knowledge of FRTP resistance welding and provide reference for the further development and application of FRTP resistance welding.

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An Electrical Resistance Joining Technology for Carbon Fiber-Reinforced Polyphenylene Sulfide Composites

Cited by 3 publications

References 25 publications

A New Design for Friction Stir Spot Joining of Al Alloys and Carbon Fiber-Reinforced Composites

A New Design for Friction Stir Spot Joining of Al Alloys and Carbon Fiber-Reinforced Composites

Response Surface Methodology Optimization of Resistance Welding Process for Unidirectional Carbon Fiber/PPS Composites

Advances in Resistance Welding of Fiber-Reinforced Thermoplastics

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