High-speed joining of hybrid metal-polymer joints during the friction-assisted joining process

Lambiase, F.; Grossi, V.; Paoletti, A.

doi:10.1016/j.compstruct.2021.114890

Cited by 16 publications

(3 citation statements)

References 15 publications

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“…Problem occur during the forming process of such hybrids, because both materials exhibit completely different mechanical properties [44,45]. The formation of such joints is based mainly on the mechanical "hooking" of metal elements in polymers; however, a method based on the formation of adhesive joints using increased temperature and pressure is also used [46][47][48][49][50]. There are proposals to use 3D FDM printing to create metal-polymer joints, although they are based on 3D printing by applying polymers to polymers, thereby creating a rivet that holds the metal part [51].…”

Section: Introductionmentioning

confidence: 99%

Deposition of Biocompatible Polymers by 3D Printing (FDM) on Titanium Alloy

2022

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Nowadays, the replacement of a hip joint is a standard surgical procedure. However, researchers have continuingly been trying to upgrade endoprostheses and make them more similar to natural joints. The use of 3D printing could be helpful in such cases, since 3D-printed elements could mimic the natural lubrication mechanism of the meniscus. In this paper, we propose a method to deposit plastics directly on titanium alloy using 3D printing (FDM). This procedure allows one to obtain endoprostheses that are more similar to natural joints, easier to manufacture and have fewer components. During the research, biocompatible polymers suitable for 3D FDM printing were used, namely polylactide (PLA) and polyamide (PA). The research included tensile and shear tests of metal–polymer bonds, friction coefficient measurements and microscopic observations. The friction coefficient measurements revealed that only PA was promising for endoprostheses (the friction coefficient for PLA was too high). The strength tests and microscopic observations showed that PLA and PA deposition by 3D FDM printing directly on Ti6Al4V titanium alloy is possible; however, the achieved bonding strength and repeatability of the process were unsatisfactory. Nevertheless, the benefits arising from application of this method mean that it is worthwhile to continue working on this issue.

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Section: Introductionmentioning

confidence: 99%

Deposition of Biocompatible Polymers by 3D Printing (FDM) on Titanium Alloy

2022

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“…However, low joint strength and additive pre-treatment requirements are considered among the major disadvantages of injection molding [ 19 ]. Friction-assisted joining is another category of metal–polymer joining where a tool plunges the metallic part into the polymer surface and rotates at a prescribed speed for a specific time [ 21 , 22 , 23 , 24 , 25 , 26 ]. An example is friction lap welding (FLW), in which the joint is created by applying pressure and heat using a non-consumable cylindrical rotating tool.…”

Section: Introductionmentioning

confidence: 99%

A Comprehensive Technical Review of the Friction Stir Welding of Metal-to-Polymer Hybrid Structures

et al. 2022

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Metal–polymer hybrid structures are becoming desirable due to their wide range of applications in the automotive, aerospace, biomedical and construction industries. Properties such as a light weight, high specific strength, and design flexibility along with the low manufacturing costs of metal–polymer hybrid structures make them widely attractive in several applications. One of the main challenges that hinders the widespread utilization of metal–polymer hybrid structures is the challenging dissimilar joining of metals to polymers. Friction stir welding (FSW) shows a promising potential in overcoming most of the issues and limitations faced in the conventional joining methods of such structures. Several works in the literature have explored the FSW of different metal-to-polymer combinations. In some of the works, the joints are examined based on processing parameter optimization, microstructural characteristics, and mechanical performances. It is, therefore, important to summarize the findings of these works as a means of providing a reference to researchers to facilitate further research on the utilization of FSW in joining metals to polymers. Thus, this work aims to present a comprehensive technical review on the FSW technique for joining metals to polymers by reviewing the reported literature findings on the impact of materials, tools, process parameters, and defects on the strength and microstructure of the produced joints. In addition, this work reviews and presents the latest practices aiming to enhance the metal–polymer joint quality that have been reported in the literature.

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“…FSJ, based on the friction stir welding concept, is claimed to include the advantages of both mechanical and chemical joining mechanisms for the metal-polymer joints. Compared to the other joining methods, FSJ also needs less surface preparation and provides shorter joining time, as well as low energy consumption and high economic advantages [20][21][22][23].…”

Section: Introductionmentioning

confidence: 99%

Improving appearance and mechanical strength of aluminum-polypropylene/talc composite friction stir joint using a novel tool design

Shiravi

Movahedi

Ozlati

2022

Int J Adv Manuf Technol

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In this research, friction stir joining of aluminum-polypropylene/talc composite was investigated due to the numerous applications of aluminum-polymer joints in automotive and aerospace industry. A novel tool design, including a rotary/stationary holder was used to improve the appearance and mechanical performance of friction stir lap joints by preventing the mixed molten polymer and aluminum particles from exiting the stirred zone. Effect of tool transverse speed on the joint microstructure and strength was investigated. Using the rotary/stationary holder, tensile-shear strength of the joints increased (by ~45% to ~220% at various transverse speeds). Since during the tensile-shear test, all joints failed from the aluminum/stirred zone interface, joint strength was affected by the formation of anchor-like aluminum pieces in the composite substrate as the mechanical locks, reaction layer at the joint interface and large voids near the aluminum/stirred zone interface. Joining at the optimum transverse speed led to the highest tensile-shear peak load of 315 N.

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High-speed joining of hybrid metal-polymer joints during the friction-assisted joining process

Cited by 16 publications

References 15 publications

Deposition of Biocompatible Polymers by 3D Printing (FDM) on Titanium Alloy

Deposition of Biocompatible Polymers by 3D Printing (FDM) on Titanium Alloy

A Comprehensive Technical Review of the Friction Stir Welding of Metal-to-Polymer Hybrid Structures

Improving appearance and mechanical strength of aluminum-polypropylene/talc composite friction stir joint using a novel tool design

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