Influence of the Production Process on the Binding Mechanism of Clinched Aluminum Steel Mixed Compounds

The multi-material design and the adaptability of a modern process chain require joining connections with specifically adjustable mechanical, thermal, chemical or electrical properties, whereby previous considerations have focused primarily on the mechanical properties. With clinching, the multitude of possible combinations of requirements, materials and component or joint geometry makes it impossible to determine these joint properties empirically. As a result of the established and empirically based procedure, no model exists to date that considers all questions of joinability, i.e. the materials (suitability for joining), the design (joining safety) and the production (joining possibility) and allows a calculation of the achievable properties. It is therefore necessary to describe the physical properties of the joint as a function of the three bonding mechanisms force closure, form closure and material closure in relation to the application. This approach enables the illustration of the relationships along the causal chain "joint requirement - binding mechanism - joining parameters". In this way the adaptability of the mechanical joining technology can be improved. A geometric comparison is made using metallographic cross sections, of clinched joints of the combination of aluminum and steel. The torsional testing of the rotationally symmetric clinching points for detection of the mechanical stress state are qualified as examination method and technological test. By measuring the electrical resistance in the base material, in the clinch joint and during the production cycle (after clinching, before precipitation hardening and after precipitation hardening), this change in the stress state can also be detected.

Adhesion of Multifunctional Substrates for Integrated Cure Monitoring Film Sensors to Carbon Fiber Reinforced Polymers

During fiber composite production, the quality of the manufactured parts can be assured by measuring the progress of the curing reaction. Dielectric film sensors are particularly suitable for this measurement task, as they can quantify the degree of curing very specifically and locally. These sensors are usually manufactured on PI films, which can lead to delaminations after integration. Other authors report that this negative influence can be reduced by miniaturization and a suitable shaping of the sensors. This article pursues as an alternative, a novel approach to achieve a material closure instead of a geometrically generated form closure by choosing suitable thermoplastic materials. Thermoplastic films made of PEI, PES and PA6 are proposed as carrier substrates for thin film sensors. They are investigated with regard to their mechanical effects in FRP. The experiments show that the integration of PES and PEI in FRP has the best shear strength, but PA6 leads to a higher critical energy release rate during crack propagation in mode I. For PI, a locally strongly scattering critical energy release rate was observed. Neither in tensile nor in Compression After Impact (CAI) tests a significant influence of the films on these characteristic values could be proven.