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

Abstract

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.

Investigation of the Fracture Behaviour of Al–CFRP Cross-Lap Joint Fabricated by Coaxial One-Side Resistance Spot Welding

“…With the development in technology, some thermal-based joining technologies have been proposed to connect metal and CFRP. Thermal-based joining aims to melt partially plastic at the metal–CFRP interface and form chemical bonds or micro-mechanical interlocking to provide cohesion, thereby eliminating the extra weight induced by the fastener and the adhesive [ 5 ]. The mechanical performance of metal–CFRP joints is the most critical factor in evaluating the quality and reliability of the thermal-based joining technology.…”

Study of mechanical behaviour & microstructural properties on friction stir welded aluminium alloys 6082 - t6&8011

“…Ghosh et al optimized the friction stir welding process parameters of dissimilar aluminium alloys has wide variety of application in defense and aerospace industries demonstrates a significant increase in binding strength compared to the AA 6XXX Series, it inspects between the wrought alloy founded that interface microstructure within the weld nugget zone in retreating side it promotes the finer distribution of SiC in rich and exhibits superior quality [2]. T Joint takes place by using the FSW carried in the dissimilar aluminium alloys in different welding conditions with the existence of the cladding layer two plates are holded in the T joint configuration in the fsw machine and the welding process performes by varying the tool rotational rates and travel speeds with the tapered cylindrical pin [9].To create lightweight bodywork, friction stir welding (FSW) of aluminum alloys is a cuttingedge manufacturing technique. Deformation's impact on FSW's corrosion behavior.…”

Feasibility study of friction stir joining of aluminium with carbon fibre reinforced thermoplastic composite

“…In particular in the automotive and aerospace industries, classical structural materials are continuously replaced by lightweight metals, such as aluminium or magnesium alloys, as well as polymeric composites. 1 By reducing weight of vehicles by 10%, fuel efficiency can be enhanced by around 7%, and consequently CO 2 emissions are lowered. 1 Lightweight structures of dissimilar structural materials, in weight savings.…”

“…1 By reducing weight of vehicles by 10%, fuel efficiency can be enhanced by around 7%, and consequently CO 2 emissions are lowered. 1 Lightweight structures of dissimilar structural materials, in weight savings. [2][3][4] The Boeing B787 Dreamliner and Airbus A350 XWB are examples of extensive use of carbon fibre reinforced polymer composites in large load-carrying structures, containing 50% composites by weight.…”

“…On the other hand, mechanical fastening leads to stress concentrations due to through-holes and additional weight by metal fasteners. 1 Solid-state welding processes, for instance the well-known Friction Stir Welding (FSW) invented by TWI or the derived refill Friction Stir Spot Welding (refill FSSW) can overcome some of these limitations and are efficient due to short joining cycles. 1,8 Further welding processes for joining polymer-metal structures are ultrasonic 9 or laser welding.…”