Analysis of the Bonding Behavior and Joining Mechanism during Friction Press Joining of Aluminum Alloys with Thermoplastics

Wirth, Franz; Zaeh, Michael F.; Krutzlinger, M.; Silvanus, J.

doi:10.1016/j.procir.2014.06.134

Cited by 18 publications

(12 citation statements)

References 7 publications

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“…An analysis study by Wirth on the bonding behavior and joining mechanism of aluminum and thermoplastics recommended optimal conditions such as holding time, axial force, etc. [33]. High lap joint quality with shear strength of 5-8 MPa was reported in a case study of aluminum and laser transmission joints of nylon [34] and PMMA [35] where in both cases the temperature reached the melting temperature of the thermoplastics.…”

Section: Introductionmentioning

confidence: 86%

Effect of Surface States on Joining Mechanisms and Mechanical Properties of Aluminum Alloy (A5052) and Polyethylene Terephthalate (PET) by Dissimilar Friction Spot Welding

Yusof

Muhamad

Moshwan

et al. 2016

Metals

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Abstract:In this research, polyethylene terephthalate (PET), as a high-density thermoplastic sheet, and Aluminum A5052, as a metal with seven distinct surface roughnesses, were joined by friction spot welding (FSW). The effect of A5052's various surface states on the welding joining mechanism and mechanical properties were investigated. Friction spot welding was successfully applied for the dissimilar joining of PET thermoplastics and aluminum alloy A5052. During FSW, the PET near the joining interface softened, partially melted and adhered to the A5052 joining surface. The melted PET evaporated to form bubbles near the joining interface and cooled, forming hollows. The bubbles have two opposite effects: its presence at the joining interface prevent PET from contacting with A5052, while bubbles or hollows are crack origins that induce crack paths which degrade the joining strength. On the other hand, the bubbles' flow pushed the softened PET into irregularities on the roughened surface to form mechanical interlocking, which significantly improved the strength. The tensile-shear failure load for an as-received surface (0.31 µm R a ) specimen was about 0.4-0.8 kN while that for the treated surface (>0.31 µm R a ) specimen was about 4.8-5.2 kN.

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Section: Introductionmentioning

confidence: 86%

Effect of Surface States on Joining Mechanisms and Mechanical Properties of Aluminum Alloy (A5052) and Polyethylene Terephthalate (PET) by Dissimilar Friction Spot Welding

Yusof

Muhamad

Moshwan

et al. 2016

Metals

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show abstract

“…The importance of fuel consumption reduction and protection of environment by reducing CO 2 emissions has led automotive and aerospace industries to build lightweight components with a high strength-to-weight ratio by considering the safety performance [1,2]. In addition, the need for materials with thermal and sound insulation that can be affordable, lightweight and corrosion resistant in these industries, as well as in the construction and ship building industries, stresses the importance of the production of new materials with these characteristics [3,4].…”

Section: Introductionmentioning

confidence: 99%

Investigation of the bonding strength of the stainless steel 316L/polyurethane/stainless steel 316L tri-layer composite produced by the warm rolling process

Andani

Daneshmanesh

Jahromi

2018

Jnl of Sandwich Structures & Materials

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In this study, a metal/polymer tri-layer composite was produced by direct adhesion (without adhesive), and mechanical locks were created using the warm rolling process. The effect of the process parameters including preheating temperature, rolling speed, thickness reduction, surface roughness, and the orientation of the surface scratches on the bond strength between layers was investigated. The results indicated that the suitable polymer fluidity and penetration, to provide stronger mechanical locks and higher bond strengths, could be achieved at an optimum preheating temperature and a rolling speed of 240°C and 36 r/min, respectively. In addition, the most appropriate surface pretreatment was obtained in the wire brush in the rolling direction mode with the surface roughness of 0.65 µm, so that the failure mechanism in this case was cohesive and the optimum thickness reduction was achieved at 40%. Furthermore, the mechanical properties of the sandwich sheet with highest bonding strength were evaluated.

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“…Besides the design flexibility, complex components usually involve many subparts being joined together. To this end, welding processes are generally employed; however, in order to overcome the principal limitations of such processes either improving the joint quality or reducing the processing time, new joining techniques are being developed to produce metalpolymer joints and polymer-polymer joints such as clinching [1,2], self-pierce riveting [3], laser welding [4], friction press joining [5], friction riveting [6] and friction lap welding [7]. To ensure the mechanical performances of the assembled parts, the choice of the joining process is a key issue.…”

Section: Introductionmentioning

confidence: 99%

Analysis of forces and temperatures in friction spot stir welding of thermoplastic polymers

Paoletti

Lambiase

Ilio

2015

Int J Adv Manuf Technol

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The present investigation analyses the force and torque developing during friction stir spot welding (FSSW) of thermoplastic sheets varying the main process parameters. In addition, measurements of the tool temperature and those of the material close to the welding region were carried out to better understand the variation of the forces during FSSW and quality of the joints. Experimental tests involving an instrumented drilling machine were performed on polycarbonate sheets. The study involved the variation of dwell time, tool plunge rate and rotational speed. Mechanical characterization and dimensional analysis of the joints were performed in order to assess the influence of the process parameters on the joint quality under considered processing conditions. According to the achieved results, using low values of the plunging speed has beneficial effects on both the process (reduction in the force and torque) and the mechanical behaviour of the joints. Increasing the tool rotational speed results in reduced processing forces and higher material mixing and temperature. The dwell time has a negligible effect on developing forces while it highly influences the material temperature, dimension of the welded region and consequently the mechanical behaviour of the joint.

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Analysis of the Bonding Behavior and Joining Mechanism during Friction Press Joining of Aluminum Alloys with Thermoplastics

Cited by 18 publications

References 7 publications

Effect of Surface States on Joining Mechanisms and Mechanical Properties of Aluminum Alloy (A5052) and Polyethylene Terephthalate (PET) by Dissimilar Friction Spot Welding

Effect of Surface States on Joining Mechanisms and Mechanical Properties of Aluminum Alloy (A5052) and Polyethylene Terephthalate (PET) by Dissimilar Friction Spot Welding

Investigation of the bonding strength of the stainless steel 316L/polyurethane/stainless steel 316L tri-layer composite produced by the warm rolling process

Analysis of forces and temperatures in friction spot stir welding of thermoplastic polymers

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