Innovative Solid-state Spot Joining Methods for Fiber Composites and Metal-polymer Hybrid Structures

8/12/2019 Innovative Solid-state Spot Joining Methods for Fiber Composites and Metal-polymer Hybrid Structures

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Joining in Car Body 2012, Bad Nauheim, 18.04.2012

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Workgroup Group @ HZG

- Students: L Postdoc, R PhD, P MSc and L undergraduation students

Integrated in the Institute of Polymer Composites at Hamburg

University of Technology (TUHH) through anAssistant Professorship

in Joining of Polymer-Metal Hybrid Structures

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Process development

Properties of the interface (bonding mechanisms)

Mechanical, physical-chemical, thermal and microstructural properties

of polymer composites / lightweight metal hybrid structures

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Car Manufacturers

Suppliers:

Material Supplier

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- Different Cohesion and Surface Energies. Low

miscibility!

- Difference in Coefficient of Thermal Expansion

and Heat Capacitycan lead to separation

distortion of parts

- Reduced Thermal Resistance of the polymer

can lead to thermal degradation

K#4 6#1.#*'&(*

- Avoid damage or modification of the network of

fibres


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CFKMagnesium

Increased use of polymer-metal hybrid structures in the engineering

applications (weight reduction and decrease in CO2 emissions )

Available joining methods for those structures are either complex,

expensive or not environmental friendly


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Joining Technologies for Polymer-Metal Hybrid Structures

(S. Amancio and J.F. dos Santos, Polym. Eng. Sci., 2008)


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15/47Amancio, 18.04.12 15Blaga 02.04.2012 15

FricRiveting is a innovative spot joining

technique for polymer-metal structures(US Patent US 7 525 149 B2 (2009))

Based on mechanical fastening and

friction welding

Cylindrical metallic rivet is used to join

thermoplastic components

Prize-winning joining technology: ? PQQ K4'6&'#" B(+,'"0 AE%41* i B(",( G15EC

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F4'6R'$(&'"0

Positioning

of the

Partners

Rotating Rivet

Insertion &

Polymer Melting

Plasticizing

of the Rivet

& Forging

Anchoring of the

forged rivet &

Joint

Consolidation

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Principles of the process


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Microstructure: PEI / Al 2024

Polymer-Polymer Interface

Metal-Polymer

Interface

(adhesion)

PAGE 17

F4'6R'$(&'"0

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Base

Material


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Glass fiber woven is shifted to about 45 degrees to theupper face of the composite

Fiber network remains in contact with the rivet shaft

Reduced amount of thermal flaws

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Ti alloy / GFR PEI: Microstructure


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Al 2024 / PEI :Tensile Strength (Avg. Curve of 5 Samples)

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Al 2024 / PEI : Lap Shear Strength (avg. of 5 samples, ASTM D5961)

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h MMTd k QTL >9%


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H844("& ;($(+#.1("&*

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Avg. lap shear strength of 200 MPa

Failure through shear of the metallic rivet

Friction riveted have similar behavior and

mechanical performance as bolted joints!

Ti alloy / GFR PEI : Lap Shear Strength (ASTM D5961)

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Current Investigations

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=8#&'$( 9+%*&'6* b =+ %++#7*(C. Rodrigues, MSc-Thesis)

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K4'6&'#"


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- Developed and patented by HZG

(US Patent No. 6722556B2)

- Refilled Spot (no keyhole in the

welding region)

- For both metals and polymers,

FSpW shows better mechanical

properties than FSSW

- Similar or better mechanical

performance in comparison to other

spot welding techniques1

1 P. Oliveira, S. Amancio-Filho, J. dos Santos, E. Hage Jr., Mater. Lett., 64, 2098-101 (2010)

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European Pat. Appl. EP 09015014

Shallow tool plunges (0,2-0,3 mm)

Metallic material is heated up and formed locally

Joint achieved by adhesion forces (consolidated polymer) and

mechanical interlocking (metallic nub)

Distinction Prize (Sonderwrdigung), 2011

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Alclad 2024-T3 / PPS-CF

Microstructure

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New spot joining process for thermoplastics and metals (HZG

Patent, DE 10 2005 057 891.8 2005)

Based on principles from injection moulding, adhesive

bonding and staking

Tooling: Electrical Heating and Frictional Heating

Prize of PPS-2010 Banff, Canada

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Frictional heatingElectrical heating


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f+(6&4'6%+ E(%&'"0 !H@

Main parameters: heating time and heating

temperature


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ABIBE, A.B et al., J Thermop Comp Mat, 2011

Polymer

Metal

f+(6&4'6%+ E(%&'"0 !H@

Excellent mechanical performance

Better cavity filling results in higher

global

Mechanical properties

Limitations: long joining times andhigh energy consumption

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K4'6&'#"-5%*(, !H@

Energy efficient

Faster cycles

Simpler tooling

Main Parameters

- Rotational speed

- Joining time

- Joining pressure

41

fm8'.1("&J RSM400


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PA66 30%GF / Al 2024( Process duration: 3s -5s)

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Little or absent surface cleaning /preparation.

Easy accessibility

Joining is independent of position.

Short joining cycles (0,5 to 10 s)

A wide range of materials and can bejoined

Hermetic sealed joints

Simple and low cost machinery.Robotic application is also possible

Joints with good tensile and shearperformance

\'1'&%&'#"*

Only spot-like joints

Not applicable for thermoset polymers,

without selecting optimized joint

geometries

non-reopenable joints

Minimum thickness of the polymeric

partner(s). Nevertheless, this can be

reduced by altering geometry of joint

Tool wear in FSpW of CFRP(not in FSpJ!!!)

PAGE 43

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Joinability of Polymer-Metal structures is strongly dependent on the

level of properties dissimilarity

Solid-State Joining Processes are innovative technologies for

environmental friendly and cost effective lightweight design

The know-how in Polymer-Metal Joining is an asset for the

increasing market competition in the field of multi-material

lightweight design

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Alternative processes to adhesively bonded, riveted and bolted joints?

Adequate for joints between TPO and Engineering Plastics andComposites (FricRiveting)

As local reinforcement for bonded structures (FSpJ)?

As alternative to currently available spot welding (FSpW)

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Financial Support

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Prof. Dr.-Ing. Sergio AmancioE-mail: [email protected]

Tel.: +49 4152 872066

Helmholtz-Zentrum Geesthacht,

Zentrum fr Material -und Kstenforschung GmbH. All rights reserved.

Confidential and p roprietary document.

This document and all in formation contained herein is the sole

property of Helmholtz-Zentrum Geesthacht,

Zentrum fr Material -und Kstenforschung GmbH. No intellectual

property rights are granted by the delivery of this document or

the disclosure of its con tent. This document shall not be

reproduced or disclosed to a third party without the express

written consent of Helmholtz-Zentrum Geesthacht,Zentrum fr Material -und Kstenforschung GmbH. This

document and its content shall not be used for any purpose

other than that for which it is supplied.

The statements made herein do not constitute an offer. They

are based on the mentioned assumptions and are expressed

in good faith. Where the supporting grounds for these

statements are not shown, Helmholtz-Zentrum Geesthacht,

Zentrum fr Material-und Kstenforschung GmbHwill

be pleased to explain the basis thereof

Innovative Solid-state Spot Joining Methods for Fiber Composites and Metal-polymer Hybrid Structures

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