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

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.

Microstructure and mechanical property improvement of dissimilar metal joints for TC4 Ti alloy to Nitinol NiTi alloy by laser welding

2021 ◽  
Vol 0 (0) ◽  
Author(s):  
Yan Zhang ◽  
DeShui Yu ◽  
JianPing Zhou ◽  
DaQian Sun ◽  
HongMei Li
Keyword(s):  
Tensile Strength ◽  
Laser Welding ◽  
Mechanical Performance ◽  
Niti Alloy ◽  
Welding Process ◽  
Ti Alloy ◽  
The One ◽  
Fusion Weld ◽  
Welding Processes ◽  
Cu Interlayer

Abstract To avoid the formation of Ti-Ni intermetallics in a joint, three laser welding processes for Ti alloy–NiTi alloy joints were introduced. Sample A was formed while a laser acted at the Ti alloy–NiTi alloy interface, and the joint fractured along the weld centre line immediately after welding without filler metal. Sample B was formed while the laser acted on a Cu interlayer. The average tensile strength of sample B was 216 MPa. Sample C was formed while the laser acted 1.2 mm on the Ti alloy side. The one-pass welding process involved the creation of a joint with one fusion weld and one diffusion weld separated by the remaining unmelted Ti alloy. The mechanical performance of sample C was determined by the diffusion weld formed at the Ti alloy–NiTi alloy interface with a tensile strength of 256 MPa.

scholarly journals Development of laser welding of high strength aluminium alloy 2024-T4 with controlled thermal cycle

2020 ◽  
Vol 326 ◽  
pp. 08005
Author(s):  
Mete Demirorer ◽  
Wojciech Suder ◽  
Supriyo Ganguly ◽  
Simon Hogg ◽  
Hassam Naeem
Keyword(s):  
Laser Beam ◽  
Laser Welding ◽  
Heat Input ◽  
Thermal Cycle ◽  
Laser Beam Welding ◽  
Base Material ◽  
High Strength ◽  
Cooling Rates ◽  
Aa 2024 ◽  
Welding Processes

An innovative process design, to avoid thermal degradation during autogenous fusion welding of high strength AA 2024-T4 alloy, based on laser beam welding, is being developed. A series of instrumented laser welds in 2 mm thick AA 2024-T4 alloys were made with different processing conditions resulting in different thermal profiles and cooling rates. The welds were examined under SEM, TEM and LOM, and subjected to micro-hardness examination. This allowed us to understand the influence of cooling rate, peak temperature, and thermal cycle on the growth of precipitates, and related degradation in the weld and heat affected area, evident as softening. Although laser beam welding allows significant reduction of heat input, and higher cooling rates, as compared to other high heat input welding processes, this was found insufficient to completely supress coarsening of precipitate in HAZ. To understand the required range of thermal cycles, additional dilatometry tests were carried out using the same base material to understand the time-temperature relationship of precipitate formation. The results were used to design a novel laser welding process with enhanced cooling, such as with copper backing bar and cryogenic cooling.

Determination of Heat Input in Tungsten Inert Gas and Laser Welding of Type Optim 960 QC Structural Steel Using Adams’ Equation for 2-D Heat Distribution

2017 ◽  
Vol 750 ◽  
pp. 45-52
Author(s):  
Sveto Cvetkovski
Keyword(s):  
Laser Welding ◽  
Heat Input ◽  
Arc Welding ◽  
Research Work ◽  
Laser Beam Welding ◽  
Peak Temperature ◽  
Efficiency Coefficient ◽  
Zone Recrystallization ◽  
Welding Processes

The heat input during conventional arc welding processes can be readily calculated knowing the power taken from the power source. The efficiency coefficient can be taken from the appropriate literature standards. Here, the intention of the performed research work was to develop a procedure for determination of heat input in arc and laser welding processes implementing Adams equation - modified Rykalin equation for two dimensional heat distributions (2-D). To realize this idea, it is necessary to determine two characteristic temperatures points in the HAZ with known peak temperature, and to determine distance between them. Implementing measured values for distance in Adams’ equation, heat input in arc welding can be directly determined in arc welded joints.In laser beam welding, the absorption of the beam in the metal is not known, so that the welding heat input cannot be calculated directly, and direct implementation of Adam’s equation is not possible i.e. absorption coefficient has to be determined first, and after that calculation of heat input is possible.The peak temperatures corresponding to specific microstructures can be obtained by performing welding simulation, by the Gleeble 1500 simulator in our case. As one of the peak temperatures, the melting temperature can be used corresponding to the fusion line, so that at least one characteristic peak temperature such as coarse grain zone, fine grin zone, intercritical zone, recrystallization, has to be determined by the simulation.Performed research showed that obtained values for heat input using Adam’s equation correspond pretty well with standard equation for heat input in arc welding.

Brazing of transparent polycrystalline Al2O3 and GH99 with the assistance of (Cu, Ni) solid solution cladding layer

2020 ◽  
Author(s):  
Bo Zhang ◽  
Lixia Zhang ◽  
Zhan Sun ◽  
Jicai Feng
Keyword(s):  
Solid Solution ◽  
Shear Strength ◽  
Mechanical Response ◽  
Mechanical Performance ◽  
Joint Shear Strength ◽  
Brazed Joints ◽  
Brazed Joint ◽  
Solution Layer ◽  
Cu Foil ◽  
Pure Cu

Abstract In this study, pure Cu foil was firstly vacuum cladding on the GH99 alloy (GH99) surface to prepare a (Cu, Ni) solid solution layer. By varying the cladding temperatures, (Cu, Ni) solid solution layers with different Ni contents were achieved. The vacuum cladding process was then followed by vacuum brazing of the Cu-coated GH99 to transparent polycrystalline Al 2 O 3 (TPA). Typical microstructure of the TPA/Cu-cladding GH99 brazed joint was characterized. The effects of different cladding temperatures on microstructural evolution and mechanical response of the brazed joints were discussed. By varying the cladding temperature, different thickness of the reaction layer at the braze filler/TPA interfaces can be achieved, which shows a strong correlation with the mechanical performance of the brazed joint. The maximum shear strength of the brazed joint reached 103 MPa when the cladding temperature was 1105 ºC. Compared with the directly brazed joint, shear strength was improved by 472%.

scholarly journals Fracture Resistance of Flash Welded and Laser Welded Butt Joints in a Microalloyed HSLA Steel

2017 ◽  
Vol 754 ◽  
pp. 248-251
Author(s):  
C.A.R.P. Baptista ◽  
H.V. Ribeiro ◽  
M.S.F. Lima ◽  
Marcelo A.S. Torres ◽  
D.H.S. Costa
Keyword(s):  
Heat Input ◽  
Structural Reliability ◽  
Mechanical Performance ◽  
Welded Joint ◽  
Hsla Steel ◽  
Production Capacity ◽  
Welding Process ◽  
High Strength ◽  
Butt Joints ◽  
Welding Processes

High-strength, low-alloy (HSLA) steels are widely used in the automotive and oil industries due to their good mechanical properties and weldability. The selection of the welding process depends on several factors, including the quality of the weld bead and the production capacity. The knowledge of the mechanical performance of the welded joint is essential to ensure structural reliability. In the present work, butt joints were produced from 5 mm thick plates of a microalloyed HSLA steel by flash welding and by laser welding processes, the latter using two different heat input conditions. The microsctructure and hardness of the weld beads were evaluated. The fracture toughness of the welded joints was assessed by means of CTOD tests. The higher heat input laser welded joint presented critical CTOD comparable to that of the flash welded joint, whereas the lower heat input martensitic-bainitic laser welded joint tended to a brittle behavior.

scholarly journals Thermal Analysis Simulation for Laser Butt Welding of Inconel625 Using FEA

2018 ◽  
Vol 7 (4.10) ◽  
pp. 85 ◽  
Author(s):  
Harinadh Vemanaboina ◽  
G. Edison ◽  
Suresh Akella ◽  
Ramesh Kumar Buddu
Keyword(s):  
Heat Source ◽  
Residual Stresses ◽  
Laser Beam ◽  
Laser Welding ◽  
Process Parameters ◽  
Heat Input ◽  
Laser Beam Welding ◽  
Source Model ◽  
Heat Source Model ◽  
Welding Processes

Laser welding process is employed in the manufacturing of critical components where the final assembly units necessitate strict tolerances like low distortions and residual stresses. Laser beam welding offers several advantages like low heat input, very narrow heat affected zone, low residual stresses, low distortions and good mechanical joint properties in the weld joints when compared to the conventional techniques like Tungsten Inert Gas Arc welding processes. However, the implementation of laser beam welding holds certain challenges like process parameters optimization, experimental set-up and handling and expensive costs. In order to minimize the complex experimental process, simulation techniques using Finite Element Methods (FEM) are employed in order to estimate the heat input and weld process optimization prior to the experiments. This greatly helps in the optimization and estimation of the incurred stresses and distortions with the adapted weld process with known input weld process parameters. The present work reports the Gaussian heat source model for the laser welding of Inconel 625 Alloy plates. The developed moving heat source model is presented and demonstrated with the thermal profiles in terms of the thermal histogram, temperature profiles in the joint cross sections through welded region, interface across the joints.  

scholarly journals Effect of Micro Solidification Crack on Mechanical Performance of Remote Laser Welded AA6063 Fillet Lap Joint in Automotive Battery Tray Construction

2021 ◽  
Vol 11 (10) ◽  
pp. 4522
Author(s):  
Tianzhu Sun ◽  
Pasquale Franciosa ◽  
Conghui Liu ◽  
Fabio Pierro ◽  
Darek Ceglarek
Keyword(s):  
Laser Welding ◽  
Fusion Zone ◽  
Aluminium Alloys ◽  
Mechanical Performance ◽  
Lap Joints ◽  
Fatigue Durability ◽  
Micro Cracks ◽  
Remote Laser Welding ◽  
Weld Fatigue ◽  
Weld Root

Remote laser welding (RLW) has shown a number of benefits of joining 6xxx aluminium alloys such as high processing speed and process flexibility. However, the crack susceptibility of 6xxx aluminium alloys during RLW process is still an open problem. This paper experimentally assesses the impact of transverse micro cracks on joint strength and fatigue durability in remote laser welding of AA6063-T6 fillet lap joints. Distribution and morphology of transverse micro cracks were acquired by scanning electron microscope (SEM) on cross-sections. Grain morphology in the weld zone was determined by electron backscatter diffraction (EBSD) while static tensile and dynamic fatigue tests were carried out to evaluate weld mechanical performance. Results revealed that increasing welding speed from 2 m/min to 6 m/min did not introduce additional transverse micro cracks. Additionally, welding at 2 m/min resulted in tensile strength improvement by 30% compared to 6 m/min due to the expansion of fusion zone, measured by the throat thickness, and refinement of columnar grains near fusion lines. Furthermore, the weld fatigue durability is significantly higher when fracture occurs in weld root instead of fusion zone. This can be achieved by increasing weld root angle with optimum weld fatigue durability at around 55°.

scholarly journals Geometrical Effects on Ultrasonic Al Bump Direct Bonding for Microsystem Integration: Simulation and Experiments

Micromachines ◽  
2021 ◽  
Vol 12 (7) ◽  
pp. 750
Author(s):  
Jun-Hao Lee ◽  
Pin-Kuan Li ◽  
Hai-Wen Hung ◽  
Wallace Chuang ◽  
Eckart Schellkes ◽  
...  
Keyword(s):  
Shear Strength ◽  
Joint Strength ◽  
Maximum Stress ◽  
Geometrical Parameters ◽  
Experimental Demonstration ◽  
Joint Shear Strength ◽  
Element Analysis ◽  
Ultrasonic Bonding ◽  
Simulation Results ◽  
Geometrical Effects

This study employed finite element analysis to simulate ultrasonic metal bump direct bonding. The stress distribution on bonding interfaces in metal bump arrays made of Al, Cu, and Ni/Pd/Au was simulated by adjusting geometrical parameters of the bumps, including the shape, size, and height; the bonding was performed with ultrasonic vibration with a frequency of 35 kHz under a force of 200 N, temperature of 200 °C, and duration of 5 s. The simulation results revealed that the maximum stress of square bumps was greater than that of round bumps. The maximum stress of little square bumps was at least 15% greater than those of little round bumps and big round bumps. An experimental demonstration was performed in which bumps were created on Si chips through Al sputtering and lithography processes. Subtractive lithography etching was the only effective process for the bonding of bumps, and Ar plasma treatment magnified the joint strength. The actual joint shear strength was positively proportional to the simulated maximum stress. Specifically, the shear strength reached 44.6 MPa in the case of ultrasonic bonding for the little Al square bumps.

Sign in / Sign up

Export Citation Format

Share Document