Friction stir lap joining of automotive aluminium alloy and carbon-fiber-reinforced plastic

Bang, Hee-Seon; Das, Atanu; Lee, S

doi:10.1088/1757-899x/369/1/012033

Cited by 14 publications

(10 citation statements)

References 14 publications

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“…Das et al 45,46 attempted to join CF-PA66 and AA 5052 by using FSLW. The quality of the weldment is examined for the joints made with pinless and pinned tools.…”

Section: Process Developmentmentioning

confidence: 99%

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Advances in joining technologies for the innovation of 21^st century lightweight aluminium-CFRP hybrid structures

Sandeep

Natarajan

2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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In the twenty-first century, the application of carbon fiber reinforced polymer (CFRP) materials in the vehicle industry are growing rapidly due to lightweight, high specific strength, and elasticity. In the automobile and aerospace industries, CFRP needs to be joined with metals to build complete structures. The demand for hybrid structures has prompted research into the combination of CFRP and metals in manufacturing. Aluminium and CFRP structures combine the mechanical properties of aluminium with the superior physical and chemical properties of CFRP. However, joining dissimilar materials is often challenging to achieve. Various joining technologies are developed to produce hybrid joints of CFRP, and aluminium alloys include conventional adhesives, mechanical and thermal joining technologies. In this review article, an extensive review was carried out on the thermal joining technologies include laser welding, friction-based welding technologies, ultrasonic welding, and induction welding processes. The article primarily focused on the current knowledge and process development of these technologies in fabricating dissimilar aluminium and CFRP structures. Besides, according to Industry 4.0 requirements, additive manufacturing-based techniques to fabricate hybrid structures are presented. Finally, this article also addressed the various improvements for the future development of these joining technologies. Ultrasonic welding yields the maximum shear strength among the various hybrid joining technologies due to lower heat input. On the other hand, laser welding produces higher heat input, which deteriorates the mechanical performance of the hybrid joints. Surface pretreatments on material surfaces prior to joining showed a significant effect on joint shear strength. Surface modification using anodizing is considered an optimal method to improve wettability, increasing mechanical interlocking phenomena.

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“…Das et al 45,46 attempted to join CF-PA66 and AA 5052 by using FSLW. The quality of the weldment is examined for the joints made with pinless and pinned tools.…”

Section: Process Developmentmentioning

confidence: 99%

“…Surface tunnel 46 Inadequate plunge force Increase in tool tilt angle Friction spot Joining Micro voids at joint interface 53 High frictional heat causes gas entrapment during cooling Increased plunging force ejects the trapped air.…”

Section: Defect Formation In Dissimilar Metals and Cfrp Jointsmentioning

confidence: 99%

Advances in joining technologies for the innovation of 21^st century lightweight aluminium-CFRP hybrid structures

Sandeep

Natarajan

2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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“…It is reported that when the WS was increased, the heat input and the number of bubbles were reduced. 108 Similarly, comparative studies on FSW of AA5052 with polyamide 66 CFRP using pinned and pinless tools with surface ground aluminium were conducted by Bang et al (2018). The maximum joint strength obtained using a pinless tool and surface ground aluminium combination was 8 MPa.…”

Section: Fswmentioning

confidence: 99%

Review on the advancements and relevance of emerging joining techniques for aluminium to polymers/carbon fibre-reinforced polymer lightweight hybrid structures

Adarsh

Natarajan

2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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The demand for higher fuel efficiency and low fuel pollution rates leads to the development of lightweight hybrid structures. The predominant aim is to develop innovative light products with extreme versatility with bionomic and economic balance. Lightweight materials in the structures have successfully solved these problems in many industries, especially automobiles and aerospace. There is an emerging scope in producing automotive components by joining Al and Mg-based alloys with materials such as thermoplastics, ceramics and fibre-reinforced composites. Developing hybrid structures by employing metal–polymer joining is still a significant challenge. There are as many joining techniques available for joining metal with a polymer. Owing to certain drawbacks, some methods are ineffective, such as high processing time for adhesive bonding and mechanical fastening due to increased weight. The friction-based welding technique benefits hybrid joining due to its low heat-affected zone with less metallurgical damages. The study provides an overview of many emerging technologies for joining aluminium to thermoplastic/carbon fibre-reinforced polymer for lightweight structures. The paper compares different joint configurations and the effect of process variables on the microstructural and mechanical properties of hybrid joints. In addition, attempts are made to comprehend contemporary developments in the finite element simulation studies of hybrid structures. The paper also highlights recently developed strategies and gaps in areas where future studies might be focussed. Thus, the paper gives an overview of the advancements and relevance of the emerging joining technique for aluminium to polymers/carbon fibre-reinforced polymer hybrid structures.

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“…The results show that increasing the surface roughness can enhance the joint strength considerably due to the formation of mechanical interlocking. Bang et al 18 investigated the friction stir welding of polyamide 66 (PA 6.6) CFRP and AA5052 aluminum alloy sheets using pinned and pin-less tools. The results show that the pin-less tool and surface ground aluminum alloy can fabricate an appropriate joint with maximum joint strength of about 8 MPa.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation of friction stir spot welding of polymer-aluminum alloy weldments

Joudaki

Safari

Joodaki

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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The friction stir spot welding (FSSW) process is one of the main solid-state joining methods used widely for welding different materials and dissimilar metals. In this article, the welding of Polytetrafluoroethylene (PTFE) and aluminum alloy sheets by the FSSW process will be investigated experimentally. The joining of polymer (PTFE) and metal (AA1050 aluminum alloy) was done successfully. The effect of process parameters including tool rotational speed, penetration depth, initial holding time, dwell time, and tool shoulder diameter on the joint strength and elongation of the weldments will be studied using response surface methodology (RSM). The joint strength was increased by creating a threaded hole in the aluminum sheet. A mechanical lock was created between the softened PTFE and the edge of the threaded hole. The shear-tensile tests have been carried out for 32 designed experiments. The results show that the joint strength increased by increasing the initial holding time due to the better wettability of PTFE and aluminum sheet. The joint strength increased by increasing the tool rotational speed and tool diameter (better pouring of the hole and formation of the mechanical lock). Two different fracture modes have been observed in the samples: (1) fracture in the peripheral area of the joint (partial interfacial fracture mode) and (2) fracture in the mechanically locked area (pull-out mode with tearing).

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Friction stir lap joining of automotive aluminium alloy and carbon-fiber-reinforced plastic

Cited by 14 publications

References 14 publications

Advances in joining technologies for the innovation of 21^st century lightweight aluminium-CFRP hybrid structures

Advances in joining technologies for the innovation of 21^st century lightweight aluminium-CFRP hybrid structures

Review on the advancements and relevance of emerging joining techniques for aluminium to polymers/carbon fibre-reinforced polymer lightweight hybrid structures

Experimental investigation of friction stir spot welding of polymer-aluminum alloy weldments

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Friction stir lap joining of automotive aluminium alloy and carbon-fiber-reinforced plastic

Cited by 14 publications

References 14 publications

Advances in joining technologies for the innovation of 21st century lightweight aluminium-CFRP hybrid structures

Advances in joining technologies for the innovation of 21st century lightweight aluminium-CFRP hybrid structures

Review on the advancements and relevance of emerging joining techniques for aluminium to polymers/carbon fibre-reinforced polymer lightweight hybrid structures

Experimental investigation of friction stir spot welding of polymer-aluminum alloy weldments

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Product

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Advances in joining technologies for the innovation of 21^st century lightweight aluminium-CFRP hybrid structures

Advances in joining technologies for the innovation of 21^st century lightweight aluminium-CFRP hybrid structures