REW Application Possibilities for the Production of Combined Metal - Plastic Joints

Abstract

In this paper, innovative resistance element welding (REW) technology for joining galvanized steel sheets to thermoplastics (PMMA) is introduced. The essence of the innovation is in the use of a special bimetallic joining element consisting of the core made of a Sn60Pb solder, and the sleeve made of a Cu tube. During resistance heating, the solder melts, thus allowing the formation of a metallurgical joint with galvanized steel sheet. Since Sn60Pb solder melting occurs at temperatures (from 183 to 190 °C) below the thermal decomposition temperature of most thermoplastics (for PMMA above 300 °C), there is no thermal destruction of the PMMA material around the joint. The mechanical fixation of the thermoplastic material at the overlap joint is provided by the sleeve made of Cu tube which has a substantially higher strength than a Sn60Pb solder.

Use of Sn60Pb40 Solder in Resistance Element Soldering Technology

“…Another proposal on the construction of the element is presented in paper [20] this case, a bimetallic element was used in REW, which consisted of a hard metal sh and a soft solder core. A shell made of Cu provides a form-fit connection, and a c made of a Sn-Pb alloy is responsible for the metallurgical joint.…”

“…The method of manufacturing bimetallic semi-finished products and finished elements is described in more detail in articles [26,27]. Unlike the results presented in paper [20], elements with modified geometry and dimensions were used to ensure better mechanical properties for RES joints. In addition, optimized parameters for casting semi-finished products and forming elements were used, so the elements were without imperfections (wrinkles in the shell, porosity, and eccentricity of the core).…”

“…Another proposal on the construction of the element is presented in paper [20]. In this case, a bimetallic element was used in REW, which consisted of a hard metal shell and a soft solder core.…”