scholarly journals Clinching of Thermoplastic Composites and Metals—A Comparison of Three Novel Joining Technologies

Materials ◽  
2021 ◽  
Vol 14 (9) ◽  
pp. 2286
Author(s):  
Benjamin Gröger ◽  
Juliane Troschitz ◽  
Julian Vorderbrüggen ◽  
Christian Vogel ◽  
Robert Kupfer ◽  
...  
Keyword(s):  
Computed Tomography ◽  
Composite Material ◽  
Process Design ◽  
Failure Mechanisms ◽  
Thermoplastic Composites ◽  
Material Structure ◽  
Shear Tests ◽  
Load Bearing ◽  
Lap Shear ◽  
Resultant Material

Clinching continuous fibre reinforced thermoplastic composites and metals is challenging due to the low ductility of the composite material. Therefore, a number of novel clinching technologies has been developed specifically for these material combinations. A systematic overview of these advanced clinching methods is given in the present paper. With a focus on process design, three selected clinching methods suitable for different joining tasks are described in detail. The clinching processes including equipment and tools, observed process phenomena and the resultant material structure are compared. Process phenomena during joining are explained in general and compared using computed tomography and micrograph images for each process. In addition the load bearing behaviour and the corresponding failure mechanisms are investigated by means of single-lap shear tests. Finally, the new joining technologies are discussed regarding application relevant criteria.

scholarly journals Computed tomography investigation of the material structure in clinch joints in aluminium fibre-reinforced thermoplastic sheets

2021 ◽  
Author(s):  
Benjamin Gröger ◽  
Daniel Köhler ◽  
Julian Vorderbrüggen ◽  
Juliane Troschitz ◽  
Robert Kupfer ◽  
...  
Keyword(s):  
Computed Tomography ◽  
Three Dimensional ◽  
Material Design ◽  
Material Behavior ◽  
Thermoplastic Composite ◽  
Thermoplastic Composites ◽  
Material Structure ◽  
Research Activities ◽  
Reinforced Thermoplastics ◽  
Joining Process

AbstractRecent developments in automotive and aircraft industry towards a multi-material design pose challenges for modern joining technologies due to different mechanical properties and material compositions of various materials such as composites and metals. Therefore, mechanical joining technologies like clinching are in the focus of current research activities. For multi-material joints of metals and thermoplastic composites thermally assisted clinching processes with advanced tool concepts are well developed. The material-specific properties of fibre-reinforced thermoplastics have a significant influence on the joining process and the resulting material structure in the joining zone. For this reason, it is important to investigate these influences in detail and to understand the phenomena occurring during the joining process. Additionally, this provides the basis for a validation of a numerical simulation of such joining processes. In this paper, the material structure in a joint resulting from a thermally assisted clinching process is investigated. The joining partners are an aluminium sheet and a thermoplastic composite (organo sheet). Using computed tomography enables a three-dimensional investigation that allows a detailed analysis of the phenomena in different joining stages and in the material structure of the finished joint. Consequently, this study provides a more detailed understanding of the material behavior of thermoplastic composites during thermally assisted clinching.

scholarly journals Multi-Objective Optimization of Resistance Welding Process of GF/PP Composites

Polymers ◽  
2021 ◽  
Vol 13 (15) ◽  
pp. 2560
Author(s):  
Guowei Zhang ◽  
Ting Lin ◽  
Ling Luo ◽  
Boming Zhang ◽  
Yuao Qu ◽  
...  
Keyword(s):  
Signal To Noise Ratio ◽  
Welding Process ◽  
Welding Current ◽  
Resistance Welding ◽  
Thermoplastic Composites ◽  
Current Time ◽  
Process Factor ◽  
Welding Equipment ◽  
Lap Shear ◽  
Adhesive Connections

Thermoplastic composites (TPCs) are promising materials for aerospace, transportation, shipbuilding, and civil use owing to their lightweight, rapid prototyping, reprocessing, and environmental recycling advantages. The connection assemblies of TPCs components are crucial to their application; compared with traditional mechanical joints and adhesive connections, fusion connections are more promising, particularly resistance welding. This study aims to investigate the effects of process control parameters, including welding current, time, and pressure, for optimization of resistance welding based on glass fiber-reinforced polypropylene (GF/PP) TPCs and a stainless-steel mesh heating element. A self-designed resistance-welding equipment suitable for the resistance welding process of GF/PP TPCs was manufactured. GF/PP laminates are fabricated using a hot press, and their mechanical properties were evaluated. The resistance distribution of the heating elements was assessed to conform with a normal distribution. Tensile shear experiments were designed and conducted using the Taguchi method to evaluate and predict process factor effects on the lap shear strength (LSS) of GF/PP based on signal-to-noise ratio (S/N) and analysis of variance. The results show that current is the main factor affecting resistance welding quality. The optimal process parameters are a current of 12.5 A, pressure of 2.5 MPa, and time of 540 s. The experimental LSS under the optimized parameters is 12.186 MPa, which has a 6.76% error compared with the result predicted based on the S/N.

scholarly journals Additive Manufacturing-Based In Situ Consolidation of Continuous Carbon Fibre-Reinforced Polycarbonate

Materials ◽  
2021 ◽  
Vol 14 (9) ◽  
pp. 2450
Author(s):  
Andreas Borowski ◽  
Christian Vogel ◽  
Thomas Behnisch ◽  
Vinzenz Geske ◽  
Maik Gude ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Carbon Fibre ◽  
Bending Test ◽  
Thermoplastic Composites ◽  
Experimental Investigations ◽  
Material Structure ◽  
Three Point Bending ◽  
Continuous Fibre ◽  
Local Material

Continuous carbon fibre-reinforced thermoplastic composites have convincing anisotropic properties, which can be used to strengthen structural components in a local, variable and efficient way. In this study, an additive manufacturing (AM) process is introduced to fabricate in situ consolidated continuous fibre-reinforced polycarbonate. Specimens with three different nozzle temperatures were in situ consolidated and tested in a three-point bending test. Computed tomography (CT) is used for a detailed analysis of the local material structure and resulting material porosity, thus the results can be put into context with process parameters. In addition, a highly curved test structure was fabricated that demonstrates the limits of the process and dependent fibre strand folding behaviours. These experimental investigations present the potential and the challenges of additive manufacturing-based in situ consolidated continuous fibre-reinforced polycarbonate.

scholarly journals Static ultrasonic welding of carbon fibre unidirectional thermoplastic materials and the influence of heat generation and heat transfer

2021 ◽  
pp. 002199832097681
Author(s):  
F Köhler ◽  
IF Villegas ◽  
C Dransfeld ◽  
A Herrmann
Keyword(s):  
Cross Sections ◽  
Weld Line ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Thermoplastic Composites ◽  
Squeeze Flow ◽  
Anisotropic Flow ◽  
Lap Shear ◽  
Anisotropic Thermal Conductivity ◽  
Edge Defects

Ultrasonic welding is a promising technology to join fibre-reinforced thermoplastic composites. While current studies are mostly limited to fabric materials the applicability to unidirectional materials, as found in aerospace structures, would offer opportunities for joining primary aircraft structures. However, due to the highly anisotropic flow of a molten unidirectional ply undesired squeeze flow phenomena can occur at the edges of the weld overlap. This paper investigates how the fibre orientation in the plies adjacent to the weld line influences the welding process and the appearance of edge defects. Ultrasonic welding experiments with different layups and energy director configurations were carried out while monitoring temperatures at different locations inside and outside the weld overlap. The joints were characterized by single lap shear tests, analysis of corresponding fracture surfaces and microscopic cross-sections. Results showed that the anisotropic flow and the anisotropic thermal conductivity of the plies adjacent to the weld line have a distinct effect on the appearance and location of edge defects. By using energy directors that cover only part of the weld overlap area a new approach was developed to mitigate edge defects caused by the highly directional properties of the unidirectional plies.

Impact action on fiber and composite material based on it

2020 ◽  
Vol 6 ◽  
pp. 69-74
Author(s):  
V.V. Kudinov ◽  
◽  
I.K. Krylov ◽  
N.V. Korneeva ◽  
◽  
...  
Keyword(s):  
Composite Material ◽  
Deformation Behavior ◽  
Failure Mechanisms ◽  
Basic Mechanism ◽  
Impact Action ◽  
Uhmwpe Fiber ◽  
Mechanism Of Failure ◽  
First Moment ◽  
The Impact ◽  
Ib Method

The low-velosity impact properties and failure mechanisms of ultra-high molecular weight polyethylene (UHMWPE) fiber (Dyneema®SK-75) and a composite material (CM) based on it with the rigid and flexible matrices were investigated by the “Impact Break” (IB) method. A fundamental difference in deformation behavior and failure mechanisms upon impact on the UHMWPE-fiber and on the CM based on this fiber has been investigated experimentally. It is shown that impact has a little effect on the properties of UHMWPE-fiber, since it is an isotropic material. It has been established that upon impact, the properties of a fiber without a matrix were significantly higher than the properties of CM based on it. Impact action stimulates the interaction between CM components (fibers and matrix). Mechanism of stepwise deformation of anisotropic CM is occurred, which begins from the first moment of impact and ends with the destruction of the CM. A “stairway of deformation” behavior is observed in anisotropic materials. Stepwise deformation is the main form of deformation and the basic mechanism of failure of anisotropic composite materials upon impact.

scholarly journals An Experimental Study on the Shear Behaviors of Polymer-Sand Composite Materials after Immersion

Polymers ◽  
2018 ◽  
Vol 10 (8) ◽  
pp. 924 ◽  
Author(s):  
Jin Liu ◽  
Yuxia Bai ◽  
Ding Li ◽  
Qiongya Wang ◽  
Wei Qian ◽  
...  
Keyword(s):  
Composite Material ◽  
Composite Materials ◽  
Void Ratio ◽  
Dry Density ◽  
Chemical Additives ◽  
Shear Tests ◽  
Direct Shear Tests ◽  
Sand Particles ◽  
Shear Behaviors ◽  
Sand Material

Sand mixed with geotextile/fiber/cement/lime or non-traditional chemical additives to form composite materials is recognized as an effective method for improving the sand properties. In this work, the variation in properties of composite materials after immersion is reported which has rarely appeared in the literature. The focus of this study is to evaluate the shear behaviors of polymer-sand composite material after immersion with direct shear tests. Several factors which may influence the shear behaviors after immersion are analyzed. The results demonstrate that this composite material still has good shear behaviors after immersion when compared to the purely sand material. The shear behaviors are improved with an increment in the curing time, polymer content and sand dry density while there is a decrease in the shear behaviors with increasing immersion time. The interaction between sand particles and the polymer are analyzed with Scanning Electron Microscope (SEM). The polymer membranes are formed by polymer enwrapping and connected sand particles to build an elastic and viscous structure in the sand that increases the interlocking forces between sand particles and decreases the void ratio of this material. The membranes are softened in water resulting in a decrease in the shear strength. Moreover, other factors affect the shear behaviors by improving the completeness and stability of this structure.

STRENGTHENING SUPPORTING COLUMNS WITH CARBON CONCRETE

2021 ◽  
Vol 95 (3) ◽  
pp. 59-67
Author(s):  
K. HOLSCHEMACHER ◽  
◽  
A.G. BULGAKOV ◽  
W. POLIENKO ◽  
◽  
...  
Keyword(s):  
Composite Material ◽  
Building Materials ◽  
Point Load ◽  
Geometrical Parameters ◽  
Building Structures ◽  
Technical School ◽  
Load Bearing ◽  
Floor Slabs ◽  
Wide Range ◽  
The Subject

Textile concrete is an innovative composite material that has been the subject of intensive research since the beginning of the 90s of the last century. After the approval of the rules and regulations on its application to strengthen floor slabs, an important step was taken towards its entry into the building materials market. Questions regarding the reinforcement of rod-shaped load-bearing elements of building structures need additional research. Despite the great potential available, the method of tying load-bearing supports and columns is still not well understood. There is a need for research on a wide range of geometric parameters and the reinforcement systems used. The Institute of Reinforced Concrete of the Higher Technical School in Leipzig tested various samples of carbon-reinforced samples in a wide range of geometrical parameters. Their goal was to assess the effect on a possible increase in the bearing capacity of carbon-reinforced columns at a concentrated point load.

Heterogeneous FE model for single lap shear tests on FRP reinforced masonry curved pillars with spike anchors

2020 ◽  
Vol 258 ◽  
pp. 119629 ◽  
Author(s):  
Elisa Bertolesi ◽  
Gabriele Milani ◽  
Mario Fagone ◽  
Tommaso Rotunno ◽  
Ernesto Grande
Keyword(s):  
Fe Model ◽  
Shear Tests ◽  
Lap Shear ◽  
Reinforced Masonry
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