Enhancing the ultrasonic plastic welding strength of Al/CFRTP joint via coated metal surface and structured composite surface

Liu, Zeguang; Li, Yang; Liu, Weidong; Zhou, Haipeng; Ao, Sansan; Luo, Zhen

doi:10.1016/j.jmapro.2023.11.001

Cited by 8 publications

(1 citation statement)

References 42 publications

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“…Additionally, due to the concave shape of the inner contour of the micro-protrusion, this area will also act as an obstacle area to impede the upward movemen of the CFRTP. Moreover, during the welding process, the external energy input caused the resin on the CFRTP surface to melt, forming hydrogen bonding at the interface between metal and CFRTP [1,44]. This interaction increases shear and peel strength, resulting in a more durable and stable joint.…”

Section: Mechanical Locking and Hydrogen Bonding Co-effectmentioning

confidence: 99%

Design of rose thorn biomimetic micro-protrusion for metals and CFRTP easily disassembled joining

Wang,

Yasuda,

Nishikawa

2024

Eng. Res. Express

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This study focuses on the joining techniques for metals and carbon fiber reinforced thermoplastic (CFRTP) to address the pursuit of lightweight vehicles and high recycling efficiency. The innovative concept of “easy-disassembly joining” is introduced for the first time, aiming for robust joint strength and efficient disassembly/recycling of end-of-life vehicles. Inspired by rose thorn morphology and natural performances, bionic micro-protrusions are explored as intermediate structures to facilitate the easy disassembly joining between metals and CFRTP. The primary focus of the study revolves around the design strategy of micro-protrusions inspired by rose thorns. The objective is to identify the most effective micro-protrusion shapes by understanding the interplay of its geometrical parameters, including base shape, apex position, profile curvature, and stress distribution under diverse loads. Utilizing static stress numerical simulations, the study conclusively identifies an elliptical base shape with the apex positioned slightly above the right edge of the structure. The outer profile adopts a circular arc, and the inner profile follows a conical curve. This configuration effectively mitigates stress concentration at the bottom, which interfaces with the metal substrate and the smaller areas around the apex. This research introduces an innovative concept for metal-CFRTP joining and applies bionic principles in engineering solutions. By promoting lightweight and sustainable structures through enhanced disassembly efficiency, it contributes to groundbreaking advancements in the field.

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Section: Mechanical Locking and Hydrogen Bonding Co-effectmentioning

confidence: 99%

Design of rose thorn biomimetic micro-protrusion for metals and CFRTP easily disassembled joining

Wang,

Yasuda,

Nishikawa

2024

Eng. Res. Express

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Direct printing of carbon fiber reinforced thermoplastic plastic on metal sheets via fused deposition modeling assisted by laser texturing

Wang,

Liu,

Qin

et al. 2024

Polymer Composites

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Printing polymers on metal surfaces using fused deposition modeling could enhance the versatility of hybrid structures. However, the differences between metals and plastics prevented the effective spreading of molten plastic on metal surfaces, challenging reliable plastic printing on metal substrates. This study employed a nanosecond laser to fabricate laser‐textured grids of varying widths (0.2–0.5 mm) on a 6061 aluminum alloy (6061Al) surface. Carbon fiber reinforced thermoplastic plastic (CFRTP) was printed on 6061Al surface in different printing directions (0°, 45°, and 90°). The influence of laser texturing and printing direction on joint performance was evaluated. The findings indicated the laser‐texturing increased 6061Al surface roughness, enhancing wettability of CFRTP on 6061Al surface. The 45° printing direction provided the best wetting, resulting in a tensile‐shear force of 1631.7 N, 218% higher than at 90°. Optimal performance was achieved with a 0.5‐mm texture width, increasing tensile‐shear force by 180% compared to 0.2 mm and 67% compared to 0.6 mm. Interfacial stress concentration decreased and then increased with the increase of laser‐textured width and the 45° printing direction provided the longest print path and best resin spreading. This research presented a novel approach to metal‐polymer joining, with significant implications for advanced lightweight hybrid structures.Highlights Printing carbon fiber reinforced thermoplastic plastic (CFRTP) on 6061 aluminum alloy (6061Al) surface was achieved by fused deposition modeling via laser texturing. The print direction affected the wetting and spreading space of the molten resin. Pinning effect of printed CFRTP/6061Al by laser texturing was studied. The spreading and wetting of resin determined the mechanical properties.

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Investigating the impact of silane on different surface modified stainless steel ultra-thin strips and the bonding interface of stainless-steel bonded with epoxy

Wang,

Fan,

et al. 2024

Applied Surface Science

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Enhancing the ultrasonic plastic welding strength of Al/CFRTP joint via coated metal surface and structured composite surface

Cited by 8 publications

References 42 publications

Design of rose thorn biomimetic micro-protrusion for metals and CFRTP easily disassembled joining

Design of rose thorn biomimetic micro-protrusion for metals and CFRTP easily disassembled joining

Direct printing of carbon fiber reinforced thermoplastic plastic on metal sheets via fused deposition modeling assisted by laser texturing

Investigating the impact of silane on different surface modified stainless steel ultra-thin strips and the bonding interface of stainless-steel bonded with epoxy

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