Improving energy efficiency in friction assisted joining of metals and polymers

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

doi:10.1016/j.jmatprotec.2017.08.005

Cited by 62 publications

(9 citation statements)

References 20 publications

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“…Besides laser applications, welding connections between CFRTP-metals can be achieved by means of friction. Lambiase et al [23] investigated the influence of clamping frame material on the friction-assisted joining of Al-Mg aluminium plates with polyvinyl-chloride (PVC) sheets. They showed how using a clamping frame made of wood enables a faster heating process and a uniform process to increase the obtained joint's mechanical strength.…”

Section: Introductionmentioning

confidence: 99%

Feasibility Analysis of Bolted Joints with Composite Fibre-Reinforced Thermoplastics

et al. 2021

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The use of composite materials has shown steady growth in recent years due to their excellent specific mechanical properties and the possibility to reduce the weight of vehicles without impairing their safety and comfort. Continuous fibre-reinforced thermoplastic composites (CFRTP) show dynamic, acoustic, and damping properties far superior to steel and can be recycled and repaired. Their excellent properties make CFRTP good candidates for anti-vibration and shock absorbing components, however, out-of-plane mechanical properties hinder the anchoring to the vehicle’s body by means of bolted connections. The results obtained in this study show how the maximum torque that can be applied without cracks or breakage phenomena is lower than in standard steel joints. Although the preload’s value is admissible, this one is reduced over time due to relaxation phenomena associated with the viscoelastic behaviour of thermoplastic matrix. The results obtained can be improved with the integration of metal inserts in connections’ areas. In this study, a case study of a gear mount replacing the steel core with CFRTP reinforced with inserts is carried out. The results show a reduction above 50% in weight, opening the possibility of lighter structures in the automotive sector.

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Section: Introductionmentioning

confidence: 99%

Feasibility Analysis of Bolted Joints with Composite Fibre-Reinforced Thermoplastics

et al. 2021

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“…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

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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.

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“…The joint efficiency reached a maximum value of 75 per cent. Lambiase, Paoletti, Grossi and Genna (2017) examined the assisted friction technique in joining of AA5053 to polyvinyl chloride sheets. A wood clamping was used to reduce the energy loss, which increased the joint efficacy to 97 per cent.…”

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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Improving energy efficiency in friction assisted joining of metals and polymers

Cited by 62 publications

References 20 publications

Feasibility Analysis of Bolted Joints with Composite Fibre-Reinforced Thermoplastics

Feasibility Analysis of Bolted Joints with Composite Fibre-Reinforced Thermoplastics

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

Joining of AA6061 to polyvinyl chloride via hot extrusion

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