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Keywords = multimaterial car body

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25 pages, 14571 KiB  
Article
Friction Stir Spot Welding of Aluminum Alloy to Carbon Fiber-Reinforced Thermosetting Resin Coated by Thermoplastic Resin Using Tools with Different Surface Shapes
by Kazuto Tanaka and Yuki Nagae
J. Compos. Sci. 2025, 9(1), 17; https://doi.org/10.3390/jcs9010017 - 2 Jan 2025
Cited by 1 | Viewed by 1029
Abstract
To achieve carbon neutrality, a reduction in car body weight is essential. Multi-material structures that use lightweight materials such as carbon fiber-reinforced polymers (CFRP) and aluminum (Al) alloy are used to replace parts of steel components. This multi-material method requires specific joining techniques [...] Read more.
To achieve carbon neutrality, a reduction in car body weight is essential. Multi-material structures that use lightweight materials such as carbon fiber-reinforced polymers (CFRP) and aluminum (Al) alloy are used to replace parts of steel components. This multi-material method requires specific joining techniques for bonding dissimilar materials. Friction stir spot welding (FSSW) is one of the joining techniques used for joining dissimilar materials, enabling rapid and strong joints. FSSW for bonding A5052 Al alloy and carbon fiber-reinforced thermosetting resin (CFRTS) utilizing composite laminates with integrally molded thermoplastic resin in the outermost layer has been developed. However, joints using this method cause pyrolysis due to excessive frictional heating at the tool’s bottom, which may affect joint strength and promote corrosion in Al alloy. Therefore, this study developed new tools, a concave-shaped tool without a probe, a concave-shaped tool with a probe and a conventional FSSW tool, and investigated the influence of heat distribution and joint strength using the three new tools. The newly developed concave-shaped tool with a probe suppressed 7% of maximum heat input, decreased the pyrolysis area of epoxy resin by 47%, and increased joint strength by 4%. Finite element analysis also showed the suppression of heat input through the newly developed concave-shaped tool with a probe, achieved by reducing the contact area between the tool and Al alloy. Full article
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16 pages, 7064 KiB  
Article
Evaluation of Joint Strength for CFRPs and Aluminum Alloys by Friction Stir Spot Welding Using Multi-Stage Heating
by Kazuto Tanaka and Yusuke Aiba
J. Compos. Sci. 2024, 8(3), 110; https://doi.org/10.3390/jcs8030110 - 20 Mar 2024
Cited by 3 | Viewed by 1866
Abstract
To reduce car body weight, multi-material structures with lightweight materials such as carbon-fiber-reinforced plastics (CFRPs) and aluminum alloys (Als) are used to replace parts of steel components, and joining technologies for such dissimilar materials are essential. Friction stir spot welding (FSSW) is one [...] Read more.
To reduce car body weight, multi-material structures with lightweight materials such as carbon-fiber-reinforced plastics (CFRPs) and aluminum alloys (Als) are used to replace parts of steel components, and joining technologies for such dissimilar materials are essential. Friction stir spot welding (FSSW) is one of the technologies used to rapidly and strongly join dissimilar materials. FSSW for carbon-fiber-reinforced thermosetting resin (CFRTS) and Als has been developed using composite laminates with integrally molded thermoplastic resin in the outermost layer. To suppress excessive heating under the tool, this study investigated whether multi-stage heating with a non-heating time during joining affects the heat distribution and strength properties of the joint. Due to heat diffusion in Al during the non-heating time, multi-stage heating can suppress excessive heating under the tool compared to continuous heating, resulting in up to 27% larger welded area, up to 37% smaller decomposed area, and up to 6% lower maximum temperature. The use of multi-stage heating results in up to 5% higher tensile shear strength and 210% longer fatigue life by reducing the thermal decomposition of CFRP matrix resin and PA12 resin. Full article
(This article belongs to the Special Issue Metal Composites, Volume II)
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16 pages, 20816 KiB  
Article
Calculation of the Intermetallic Layer Thickness in Cold Metal Transfer Welding of Aluminum to Steel
by Zahra Silvayeh, Bruno Götzinger, Werner Karner, Matthias Hartmann and Christof Sommitsch
Materials 2019, 12(1), 35; https://doi.org/10.3390/ma12010035 - 22 Dec 2018
Cited by 11 | Viewed by 4826
Abstract
The intermetallic layer, which forms at the bonding interface in dissimilar welding of aluminum alloys to steel, is the most important characteristic feature influencing the mechanical properties of the joint. In this work, horizontal butt-welding of thin sheets of aluminum alloy EN AW-6014 [...] Read more.
The intermetallic layer, which forms at the bonding interface in dissimilar welding of aluminum alloys to steel, is the most important characteristic feature influencing the mechanical properties of the joint. In this work, horizontal butt-welding of thin sheets of aluminum alloy EN AW-6014 T4 and galvanized mild steel DC04 was investigated. In order to predict the thickness of the intermetallic layer based on the main welding process parameters, a numerical model was created using the software package Visual-Environment. This model was validated with cold metal transfer (CMT) welding experiments. Based on the calculated temperature field inside the joint, the evolution of the intermetallic layer was numerically estimated using the software Matlab. The results of these calculations were confirmed by metallographic investigations using an optical microscope, which revealed spatial thickness variations of the intermetallic layer along the bonding interface. Full article
(This article belongs to the Special Issue Welding, Joining and Coating of Metallic Materials)
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