On the feasibility of a friction-based staking joining method for polymer–metal hybrid structures

Abibe, A.B.; Sônego, Marília; Santos, Jorge F. dos; Canto, Leonardo Bresciani; Amancio‐Filho, Sergio T.

doi:10.1016/j.matdes.2015.12.087

Cited by 84 publications

(20 citation statements)

References 40 publications

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“…The first group of technologies is adhesive bonding, an established joining technology that has been extensively applied for joining similar structural configurations of metals and composites, as well as dissimilar configurations in several fields of application . The second group is called mechanical fastening, which comprises traditional technologies such as riveting, screwing, bolting, clinching, collar joining, and staking technologies , as well as recently developed technologies such as friction‐based injection clinching joining and FricRiveting (friction riveting) .…”

Section: Introductionmentioning

confidence: 99%

A review on direct assembly of through‐the‐thickness reinforced metal–polymer composite hybrid structures

Feistauer

Santos

Amancio‐Filho

2018

Polymer Engineering & Sci

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Constant efforts to reduce the structural weight of transportation systems as a solution to control emission levels are currently shaping the way modern cars and airplanes are designed and manufactured. Increased attention has been given to innovative metal–composites multi‐material concepts for the production of lightweight structures. However, the nature of these very dissimilar materials makes their joining a rather complicated task. Recently several technologies have been proposed to overcome process limitation and increase the load transfer between metal and composite in hybrid structures. One of the promising solutions is a new concept known as direct assembling with through‐the‐thickness reinforcements. In this concept, the composite material of a hybrid joint is directly assembled upon a surface‐structured metallic part. Features structured on the metallic part, by a manufacturing phase, act as a through‐the‐thickness reinforcement improving the out‐of‐plane strength and load transfer capabilities of such joints. The current status and state‐of‐art direct assembling technologies are reviewed in this article. Examples of reviewed metal structuring techniques include micromachining, stamping, Surfi‐Sculpt, additive manufacturing, cold metal transfer, and metal injection molding structuring. Direct assembling techniques addressed in this article are vacuum‐assisted resin infusion, resin transfer molding, prepreg/autoclave assembly, and ultrasonic joining. POLYM. ENG. SCI., 59:661–674, 2019. © 2018 The Authors. Polymer Engineering & Science published by Wiley Periodicals, Inc. on behalf of Society of Plastics Engineers.

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Section: Introductionmentioning

confidence: 99%

A review on direct assembly of through‐the‐thickness reinforced metal–polymer composite hybrid structures

Feistauer

Santos

Amancio‐Filho

2018

Polymer Engineering & Sci

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“…A non-consumable tool of stainless steel 316L depicted in Figure 2c was used for the F-ICJ process. The fundamentals of the F-ICJ process have been described in [18] and [19]. Joints are formed by providing frictional heat to a polymeric stud, which flows within a shear layer around the tool to create a stake.…”

Section: Methodsmentioning

confidence: 99%

Process-Related Changes in Polyetherimide Joined by Friction-Based Injection Clinching Joining (F-ICJ)

et al. 2020

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This work presents a comprehensive study on the effects of the Friction-based Injection Clinching Joining (F-ICJ) process on the microstructure and local properties of the stake head. The manuscript evaluates the consequences on the quasi-static mechanical performance of hybrid joints of amorphous polyetherimide (PEI) with aluminium AA6082. Through an overlay of microhardness map on a cross-polarized transmitted-light optical microscopy (CP-TLOM) image, two lower-strength microstructural zones in the PEI stake head were observed: a plastically-deformed zone (PDZ) and a thermo-mechanically-affected zone (PTMAZ). When compared to the base material, PDZ and PTMAZ have a reduction of 12%–16% and 8%–12%, respectively, in local mechanical properties. The reduced local strength was associated with distinct volumes of loosely packed PEI chains with unsteady chain conformation and thus larger free volume in the affected regions. The mechanical strength reduction is reversible through physical aging by thermal annealing the joints, which additionally shows that process-induced thermomechanical degradation of PEI by chain scission, as evidenced by size exclusion chromatography (SEC) analysis, does not appear to affect local mechanical strength. An evaluation of typical loading regimes of staked joints in lap shear (average ultimate force of 1419 ± 43 N) and cross tensile (average ultimate force of 430 ± 44 N) testing indicates that the process-induced changes of PEI do not compromise the global mechanical performance of such a structure. These findings provide a better understanding of the relationships between processing, microstructure, and properties for further F-ICJ process optimization.

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“…Joining of polymers, light metals and composites in multi-material components and structures is of interest in automobile and aircraft design for weight reduction [1,2]. Various methods for joining dissimilar material have been investigated, such as adhesive bonding [3][4][5][6], mechanical fastening [7,8] and welding-based methods [9][10][11].…”

Section: Introductionmentioning

confidence: 99%

Influence of PEO and mechanical keying on the strength of AA 5052 alloy/polypropylene friction stir spot welded joints

Aliasghari

Skeldon

Zhou

et al. 2019

International Journal of Adhesion and Adhesives

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A study has been carried out of the effect of plasma electrolytic oxidation (PEO) on the strength of AA 5052 alloy/polypropylene joints prepared using friction stir spot welding (FSSW). The joint strengths were determined using lap-shear tests and failure modes were investigated using scanning electron microscopy. Comparisons were made between control joints prepared with the alloy in the as-rolled condition or the as-rolled condition with a mechanical key and with PEOtreated alloy, with or without a mechanical key. Mechanical keying alone, provided by infiltration of polymer into holes of either 3 or 4.5 mm diameter drilled in the alloy, yielded enhancements of the joint strength by a factor of 1.8 and 3.8, respectively, compared with the asrolled alloy. In contrast, PEO pre-treatment provided a much greater improvement in strength, by a factor of 21.3, with no significant influence of the presence of a mechanical key. The fracture of PEO-treated joints involved a mixture of de-bonding at the polymer/coating interface, cohesive failure within the coating and ductile failure of the polymer. The latter resulted from formation of gas bubbles within the polypropylene due to thermal degradation of the polymer during FSSW. In contrast, in the absence of PEO, the fracture path of the as-rolled, and also the as-rolled and mechanically keyed, joints passed along the alloy/polypropylene interface and through gas bubbles within the polymer. The enhanced strength of the PEO-treated joints resulted from the strong polypropylene/coating bond resulting from by flow of molten polymer into the coating porosity.

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On the feasibility of a friction-based staking joining method for polymer–metal hybrid structures

Cited by 84 publications

References 40 publications

A review on direct assembly of through‐the‐thickness reinforced metal–polymer composite hybrid structures

A review on direct assembly of through‐the‐thickness reinforced metal–polymer composite hybrid structures

Process-Related Changes in Polyetherimide Joined by Friction-Based Injection Clinching Joining (F-ICJ)

Influence of PEO and mechanical keying on the strength of AA 5052 alloy/polypropylene friction stir spot welded joints

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