Clinching and torsional ultrasonic welding - An innovative process combination for joining metal-polymer hybrid structures

Multi-materials of metal-polymer and metal-composite hybrid structures (MMHSs) are highly demanded in several fields including land, air and sea transportation, infrastructure construction, and healthcare. The adoption of MMHSs in transportation industries represents a pivotal opportunity to reduce the product’s weight without compromising structural performance. This enables a dramatic reduction in fuel consumption for vehicles driven by internal combustion engines as well as an increase in fuel efficiency for electric vehicles. The main challenge for manufacturing MMHSs lies in the lack of robust joining solutions. Conventional joining processes, e.g., mechanical fastening and adhesive bonding involve several issues. Several emerging technologies have been developed for MMHSs’ manufacturing. Different from recently published review articles where the focus is only on specific categories of joining processes, this review is aimed at providing a broader and systematic view of the emerging opportunities for hybrid thin-walled structure manufacturing. The present review paper discusses the main limitations of conventional joining processes and describes the joining mechanisms, the main differences, advantages, and limitations of new joining processes. Three reference clusters were identified: fast mechanical joining processes, thermomechanical interlocking processes, and thermomechanical joining processes. This new classification is aimed at providing a compass to better orient within the broad horizon of new joining processes for MMHSs with an outlook for future trends.

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Effects of different interface conditions on energy absorption characteristics of Al /carbon fiber reinforced polymer hybrid structures for multiple loading conditions

Polymer Composites ◽

10.1002/pc.26019 ◽

2021 ◽

Author(s):

Qi‐hua Ma ◽

Fan Dong ◽

Xue‐hui Gan ◽

Tianjun Zhou

Keyword(s):

Carbon Fiber ◽

Energy Absorption ◽

Fiber Reinforced Polymer ◽

Hybrid Structures ◽

Carbon Fiber Reinforced Polymer ◽

Interface Conditions ◽

Polymer Hybrid ◽

Reinforced Polymer ◽

Multiple Loading ◽

Absorption Characteristics

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Advances in joining technologies for the innovation of 21st century lightweight aluminium-CFRP hybrid structures

Proceedings of the Institution of Mechanical Engineers Part E Journal of Process Mechanical Engineering ◽

10.1177/09544089211073027 ◽

2022 ◽

pp. 095440892110730

Author(s):

Renangi Sandeep ◽

Arivazhagan Natarajan

Keyword(s):

Shear Strength ◽

Laser Welding ◽

Heat Input ◽

Mechanical Performance ◽

Current Knowledge ◽

Ultrasonic Welding ◽

Hybrid Structures ◽

Joint Shear Strength ◽

Hybrid Joints ◽

Welding Processes

In the twenty-first century, the application of carbon fiber reinforced polymer (CFRP) materials in the vehicle industry are growing rapidly due to lightweight, high specific strength, and elasticity. In the automobile and aerospace industries, CFRP needs to be joined with metals to build complete structures. The demand for hybrid structures has prompted research into the combination of CFRP and metals in manufacturing. Aluminium and CFRP structures combine the mechanical properties of aluminium with the superior physical and chemical properties of CFRP. However, joining dissimilar materials is often challenging to achieve. Various joining technologies are developed to produce hybrid joints of CFRP, and aluminium alloys include conventional adhesives, mechanical and thermal joining technologies. In this review article, an extensive review was carried out on the thermal joining technologies include laser welding, friction-based welding technologies, ultrasonic welding, and induction welding processes. The article primarily focused on the current knowledge and process development of these technologies in fabricating dissimilar aluminium and CFRP structures. Besides, according to Industry 4.0 requirements, additive manufacturing-based techniques to fabricate hybrid structures are presented. Finally, this article also addressed the various improvements for the future development of these joining technologies. Ultrasonic welding yields the maximum shear strength among the various hybrid joining technologies due to lower heat input. On the other hand, laser welding produces higher heat input, which deteriorates the mechanical performance of the hybrid joints. Surface pretreatments on material surfaces prior to joining showed a significant effect on joint shear strength. Surface modification using anodizing is considered an optimal method to improve wettability, increasing mechanical interlocking phenomena.

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