An Innovative Friction Stir Welding Based Technique to Produce Dissimilar Light Alloys to Thermoplastic Matrix Composite Joints

Buffa, Gianluca; Baffari, Dario; Campanella, Davide; Fratini, Livan

doi:10.1016/j.promfg.2016.08.028

Cited by 33 publications

(19 citation statements)

References 12 publications

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“…The processing temperature appears to have the most prominent effect on the joint performance. Buffa et al proposed a new friction stir welding approach to join mechanically AA6082-T6 to self-reinforced polypropylene [ 58 ]. The aluminum sheet was pre-holed along both sides and placed on the top of the composite sheet.…”

Section: Mechanical Clinchingmentioning

confidence: 99%

“…A pinless tool was plunged into the aluminium sheet and moved along the longitudinal direction with constant feed rate. The heat generated by the friction force softened the top sheet and was transferred by thermal conduction to the bottom sheet [ 58 ]. Due to the friction heat and the pressure composite extrusions filled the holes in the aluminium sheet.…”

Section: Mechanical Clinchingmentioning

confidence: 99%

“…Due to the friction heat and the pressure composite extrusions filled the holes in the aluminium sheet. Once cooled down, the extruded polypropylene created a mechanical bond between the aluminium and the composite [ 58 ]. The specimens with different hole diameters and different hole pitch were subjected to shear test.…”

Section: Mechanical Clinchingmentioning

confidence: 99%

“… Failure modes in friction stir welded specimens: ( a ) shearing of the protrusions; ( b ) separation of the sheets [ 58 ]. …”

Section: Figurementioning

confidence: 99%

See 3 more Smart Citations

Mechanical Joining of Fibre Reinforced Polymer Composites to Metals—A Review. Part II: Riveting, Clinching, Non-Adhesive Form-Locked Joints, Pin and Loop Joining

Galińska

Galiński

2020

Polymers

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As fiber reinforced plastic composites gain an increasingly larger share in aerospace structures, the problem of joining them with metal elements becomes significant. The current paper is the second part of the literature review, which gathers and evaluates knowledge about methods suitable for the mechanical joining of composite and metal elements. This paper reviews the joining methods other than bolted joining, which are discussed in the first part of the review, namely self-piercing riveting, friction riveting, clinching, non-adhesive form-locked joints, pin joints, and loop joints. Some of those methods are full-fledged and employed in commercial applications, whereas others are merely ideas tested at the level of specimens. The current review describes the ideas and the qualities of the joining methods as well as the experimental work carried out so far. The summary section of this paper contains a comparison of those methods with the reference to their qualities, which is important from the point of view of a composite structure designer: possibility of the joint disassembly, damages induced in composite, complication level, weight penalty, range of possible materials to be joined, and the joint strength.

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Section: Mechanical Clinchingmentioning

confidence: 99%

Section: Mechanical Clinchingmentioning

confidence: 99%

Section: Mechanical Clinchingmentioning

confidence: 99%

“… Failure modes in friction stir welded specimens: ( a ) shearing of the protrusions; ( b ) separation of the sheets [ 58 ]. …”

Section: Figurementioning

confidence: 99%

See 2 more Smart Citations

Mechanical Joining of Fibre Reinforced Polymer Composites to Metals—A Review. Part II: Riveting, Clinching, Non-Adhesive Form-Locked Joints, Pin and Loop Joining

Galińska

Galiński

2020

Polymers

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“…Buffa et al [8] used a modified FSW process to join aluminum with polypropylene. Holes were drilled in the metal to be joined, allowing the molten plastic to flow through and thus form a form closure with the aluminum.…”

Section: Friction Press Joiningmentioning

confidence: 99%

Influence of the laser-based surface modification on the bond strength for friction press joining of aluminum and polyethylene

Meyer¹,

Wunderling²,

Zaeh³

2019

Prod. Eng. Res. Devel.

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Friction press joining is an innovative joining process for the production of plastic-metal joints without additives, in an overlap configuration. In order to achieve a high bond strength, the metallic joining partner is pretreated with laser radiation. Subsequently, heat is induced by friction and pressure during the joining process, causing the thermoplastic material to melt and adhere to the metallic joining partner. In this work, the temperature distribution during the process in the composite is analyzed and characterized. It was found that the occurring temperatures and temperature differences are not only dependent on the rotational speed, but also on the feed rate. It is also shown that the friction surface temperature can be used as an indirect control variable for a model-based, closed-loop control. Based on these findings, various surface modifications for the metallic joining partner were investigated and analyzed with regard to the maximum strength of the joint. It was observed that the highest tensile shear strength can be achieved with a quasi-chaotic nano structure. In addition, the joining compound was characterized by a thin section, facilitating the identification of specific zones in the joint. These investigations show the high potential for friction press joining of plastics and metals, and form the basis for a model-based control of the joining zone temperature.

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Effect of process parameters on the mechanical behavior of additively manufactured and FSW joined PLA wood sheets

Koçar,

Anaç,

Palaniappan

et al. 2023

Polymer Composites

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Friction stir welding (FSW), a solid‐state joining method, is an innovative technique widely employed in the welding of thermoplastics, with broad application areas such as the automotive and aerospace industries. Due to its inherent advantages, including ease of processing, biodegradability, and printability, polylactic acid (PLA) and its derivatives are notably the most commonly used polymers in 3D printing. The limited print area of 3D printers necessitates post‐production joining processes. In this study, the weldability of plates obtained using PLA Wood filament through the FSW is evaluated. For this purpose, different pin geometries (triangle, square, and screw), feed rates (20, 40, and 60 mm/min), and tool rotation speeds (1250, 1750, and 2250 rpm) are employed. Visual inspections are conducted to determine the effects of process parameters on weld quality and to identify defects in the weld region. Temperature values are measured to investigate the influence of heat generated during the FSW process. Furthermore, after determining the highest weld strengths achieved for each pin geometry, the weldability of PLA Wood material with PLA‐CF and PLA Plus materials is investigated using these parameters. The results indicate that the highest weld quality for joining PLA Wood plates is achieved using the square pin geometry, 20 mm/min feed rate, and 1750 rpm with an efficiency of 74.5%. When welding PLA Wood with PLA‐CF and PLA Plus, high weld strengths are obtained using the same process parameters (square pin, 20 mm/min, and 1750 rpm).Highlights Friction stir welding process of 3D printed PLA Wood material. Friction stir welding process of dissimilar materials pairs. Effect of welding parameters on weld strength and hardness. Identifying the fracture surface images occurring in parts after friction stir welding. Examination of temperature generation during friction stir welding.

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An Innovative Friction Stir Welding Based Technique to Produce Dissimilar Light Alloys to Thermoplastic Matrix Composite Joints

Cited by 33 publications

References 12 publications

Mechanical Joining of Fibre Reinforced Polymer Composites to Metals—A Review. Part II: Riveting, Clinching, Non-Adhesive Form-Locked Joints, Pin and Loop Joining

Mechanical Joining of Fibre Reinforced Polymer Composites to Metals—A Review. Part II: Riveting, Clinching, Non-Adhesive Form-Locked Joints, Pin and Loop Joining

Influence of the laser-based surface modification on the bond strength for friction press joining of aluminum and polyethylene

Effect of process parameters on the mechanical behavior of additively manufactured and FSW joined PLA wood sheets

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