Friction assisted joining of aluminum and PVC sheets

Abdullah

2019

MMMS

Purpose The purpose of this paper is to join AA5052 to AISI 1006 steel sheets using the spot friction forming technique. Design/methodology/approach A steel sheet was pre-holed with a diameter of 4.8 mm and pre-threaded with a single internal M6 thread. Lap joint configuration was used so that the aluminium specimen was put over steel. A rotating tool with a 10 mm diameter was used for the joining process. A Taguchi method was used to design three process parameters (plunging tool depth, rotating speed and preheating time), with three levels for each parameter. The effect of the process parameters on the joint shear strength was analysed. The macrostructure, microstructure and scanning electron microscope of the joint were investigated. The temperature distribution during the joining process was recorded. Findings The formed aluminium was extruded through the steel hole and penetrated through the thread slot. A mechanical interlock was achieved between the extruded aluminium and the steel. The plunging depth of the tool exhibited a significant effect on the joint shear strength. The joint efficiency increased gradually as the plunging depth increased. Two modes of failure were found shear and pull-out. The maximum temperature during the process reached 50 per cent of aluminium’s melting point. Originality/value For the first time, AA5052 was joined with AISI 1006 steel using a friction spot forming technique with an excellent joint efficiency.

Section: Resultsmentioning

confidence: 99%

Section: Design Of the Joining Parameters Experimentsmentioning

confidence: 99%

Spot lap joining of AA5052 to AISI 1006 by aluminium extrusion via friction forming technique

Abdullah

2019

MMMS

“…So far, aside from mechanical joining and adhesive bonding, new combined thermo-mechanical processes, i.e., friction-based processes, have been developed to produce hybrid joints on different materials, i.e., metal-to-polymer [10][11][12] as well as metal-to-composite [13,14] and composite-to-polymer [15][16][17]. However, these processes based on the friction phenomena produce poor finishing surface in the weld region and they usually require very stiff clamping systems because of the high loads involved during the processes.…”

Section: Introductionmentioning

confidence: 99%

Combined Fuzzy and Genetic Algorithm for the Optimisation of Hybrid Composite-Polymer Joints Obtained by Two-Step Laser Joining Process

et al. 2020

Self Cite

In the present work, genetic algorithms and fuzzy logic were combined to model and optimise the shear strength of hybrid composite-polymer joints obtained by two step laser joining process. The first step of the process consists of a surface treatment (cleaning) of the carbon fibre-reinforced polymer (CFRP) laminate, by way of a 30 W nanosecond laser. This phase allows removing the first matrix layer from the CFRP and was performed under fixed process parameters condition. In the second step, a diode laser was adopted to join the CFRP to polycarbonate (PC) sheet by laser-assisted direct joining (LADJ). The experimentation was performed adopting an experimental plan developed according to the design of experiment (DOE) methodology, changing the laser power and the laser energy. In order to verify the cleaning effect, untreated laminated were also joined and tested adopting the same process conditions. Analysis of variance (ANOVA) was adopted to detect the statistical influence of the process parameters. Results showed that both the laser treatment and the process parameters strongly influence the joint performances. Then, an uncertain model based on the combination of fuzzy logic and genetic algorithms was developed and adopted to find the best process parameters’ set able to give the maximum joint strength against the lowest uncertainty level. This type of approach is especially useful to provide information about how much the precision of the model and the process varies by changing the process parameters.

Advances in Materials Science and Engineering

“…In the friction-assisted joining process, heat is produced by means of a rotating tool that slightly plunges a metal sheet, which heats up by friction. Lots of works have been done to increase the joint strength and reduce the joining defects [17][18][19]. However, friction-assisted joining is a contact process, which will cause some destruction to metals.…”

Section: Introductionmentioning

confidence: 99%

Influence of Processing Parameters on Laser Direct Joining of CFRTP and Stainless Steel

Sheng

Jiao

et al. 2018

e CFRTP and the stainless steel were joined by the fiber laser, and the effect of processing parameters on the joint quality was investigated in detail. e heat-affected zone on the stainless steel and the microstructure of the joint interface were examined and analyzed. e results showed that the laser joining process refines the microstructure of the fusion and heat-affected zones in the stainless steel. And the tensile strength of the joint was affected greatly by the laser power and scanning speed but slightly by the clamping pressure. With the PPS additive, the joint shear strength could be improved, and the optimal PPS additive thickness is 300 μm. With the best parameters, joint with a shear strength of 15-17 MPa could be obtained as the laser power is 320-350 W, the scanning speed is 4-5 mm/s, the clamping pressure is about 0.5 Mpa, and the additive PPS thickness is about 300 μm.