Development of ultrasonic direct joining of thermoplastic to laser structured metal

Yeh, Ren Yu; Hsu, Ray-Quen

doi:10.1016/j.ijadhadh.2015.11.001

Cited by 56 publications

(18 citation statements)

References 13 publications

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“…However, customization of the tooling is one of the greatest limitations of this technique. Further, special structural features such as raised ridges are to be typically designed and molded into the parts to concentrate the ultrasonic wave energy and facilitate their bonding (Yadav et al , 2018; Yeh and Hsu, 2016). The technique can be applied only for overlapping and shear joints, thicker parts not more than 3 mm.…”

Section: Welding Of Three-dimensional Printed Partsmentioning

confidence: 99%

An overview on joining/welding as post-processing technique to circumvent the build volume limitation of an FDM-3D printer

Tiwary

Arunkumar

Malik³

2021

RPJ

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Purpose Three-dimensional (3D) printing, one of the important technological pillars of Industry 4.0, is changing the landscape of future manufacturing. However, the limited build volume of a commercially available 3D printer is one inherent constraint, which holds its acceptability by the manufacturing business leaders. This paper aims to address the issue by presenting a novel classification of the possible ways by which 3D-printed parts can be joined or welded to achieve a bigger-sized component. Design/methodology/approach A two-step literature review is performed. The first section deals with the past and present research studies related to adhesive bonding, mechanical interlocking, fastening and big area additive manufacturing of 3D printed thermoplastics. In the second section, the literature searches were focused on retrieving details related to the welding of 3D printed parts, specifically related to friction stir welding, friction (spin) welding, microwave and ultrasonic welding. Findings The key findings of this review study comprise the present up-to-date research developments, pros, cons, critical challenges and the future research directions related to each of the joining/welding techniques. After reading this study, a better understanding of how and which joining/welding technique to be applied to obtain a bigger volume 3D printed component will be acquired. Practical implications The study provides a realistic approach for the joining of 3D printed parts made by the fused deposition modeling (FDM) technique. Originality/value This is the first literature review related to joining or welding of FDM-3D printed parts helping the 3D printing fraternity and researchers, thus increasing the acceptability of low-cost FDM printers by the manufacturing business leaders.

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Section: Welding Of Three-dimensional Printed Partsmentioning

confidence: 99%

An overview on joining/welding as post-processing technique to circumvent the build volume limitation of an FDM-3D printer

Tiwary

Arunkumar

Malik³

2021

RPJ

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“…The joining was carried out by mechanical interlock mechanism through mixing the aluminium chips and the molten polymer. Yeh and Hsu (2016) proved that the ultrasonic direct joining technique of thermoplastic to aluminium was reliable and fast, as well as a low cost method. André et al (2016) improved the shear strength of AA2024 and CF‒PPS joint by adding PPS as film interlayer during the FSJ technique.…”

Section: Introductionmentioning

confidence: 99%

Joining of AA6061 to polyvinyl chloride via hot extrusion

Abdullah

Hussein

2019

IJSI

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Purpose The purpose of this paper is to join aluminium alloy AA6061 with polyvinyl chloride (PVC) sheets using the friction spot technique. Design/methodology/approach The AA6061 specimen was drilled with a semi-conical hole and put over the PVC specimen with a lap configuration. A friction spot technique was used to generate the required heat to melt and extrude the PVC through the aluminium hole. In this study, three process parameters were used: time, plunging depth and rotating speed of the tool. Thermal finite element model was built to analyse the process temperature. Effect of the process parameters on the joint shear strength and temperature was analysed using the design of experiments method. The microstructure investigation of the joint cross section was examined. Findings The input heat melted and extruded the polymer into the aluminium hole with the aid of tool pressure. A mechanical interlock was observed at the interface line between the polymer and aluminium. The scattered aluminium fragments into the molten polymer increased the shear strength of the joint. The hole diameter exhibited the highest effect on the joint strength compared with the other parameters. Specimen of minimum hole diameter recorded the maximum shear strength of 224 MPa. The proposed model gave a good agreement with the experimental data. Originality/value For the first time, the PVC was joined with AA6061 by the hot extrusion using the friction spot technique. The shear strength of joint reached 7.5 times of the base material (PVC).

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“…Those joints are characterized by good mechanical properties, low weight and cost. The joining process can be executed through various methods such as hot press (Hussein et al, 2017), laser joint (Yeh and Hsu, 2016), FSSW (Mubiayi and Akinlabi, 2014), FSW (Ratanathavorn and Melander, 2015), ultrasonic welding and fasteners (Patel et al, 2016). On the other hand, the engineering polymers were expanded in the engineering applications due to its low density and cost, high strength to weight ratio and excellent processing properties (Callister, 2007).…”

Section: Introductionmentioning

confidence: 99%

Shear strength and temperature distribution model of friction spot lap joint of high density polyethylene with aluminum alloy 7075

Abdullah

Hussein

2019

IJSI

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Purpose The purpose of this paper is to join a sheet of the AA7075 with the high-density polyethylene (HDPE) by a lap joint using friction spot processing and investigate the temperature distribution of joint during this process using the finite element method (FEM). Design/methodology/approach A semi-conical hole was manufactured in the AA7075 specimen and a lap joint configuration was prepared with the HDPE specimen. A rotating tool was used to generate the required heat to melt the polymer by the friction with the AA7075 specimen. The applied tool force moved the molten polymer through the hole. Four parameters were used: lower diameter of hole, rotating speed, plunging depth and time. The results of shear test were analyzed using the Taguchi method. A FEM was presented to estimate the temperature distribution of joint during the process. Findings All specimens failed by shearing the polymer at the lap joint region without dislocation. The specimens of the smallest diameter exhibited the highest shear strength at the lap joint. The maximum ranges of temperature were recorded at the contact region between the rotating tool and the AA7075 specimen. The tool plunging depth recorded the highest effect on the generated heat compared with the rotating speed and plunging time. Originality/value For the first time, the AA7075 sheet was joined with the HDPE sheet by friction spot processing. The temperature distribution of this joint was simulated using the FEM.

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Development of ultrasonic direct joining of thermoplastic to laser structured metal

Cited by 56 publications

References 13 publications

An overview on joining/welding as post-processing technique to circumvent the build volume limitation of an FDM-3D printer

An overview on joining/welding as post-processing technique to circumvent the build volume limitation of an FDM-3D printer

Joining of AA6061 to polyvinyl chloride via hot extrusion

Shear strength and temperature distribution model of friction spot lap joint of high density polyethylene with aluminum alloy 7075

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