J oiningin Car Body 2012, Bad Nauheim, 18.04.

2012
Innovative solid-state spot joining methods
for fiber composites and metal-polymer
hybrid structures
Prof. Dr.-Ing. Sergio Amancio
Institute of Materials Research - Materials Mechanics
Solid State Joining Processes (WMP)
Advanced Polymer-Metal Hybrid Structures Group
Amancio, 18.04.12
2
Contents
Introduction
Challenges and Motivation
Friction Riveting
Friction Spot Welding / J oining
ICJ Method
Final Remarks
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Introduction
PAGE 3
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PAGE 4
Helmholtz Association:
Facts and Figures
17 research centres
with more than 240 institutes
31.000 staff
9700 scientists and engineers
5.320 doctoral students
Budget: 3,3 billion
List
Helgoland
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Karlsruhe
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Oberpfaffenhofen
Helmholtz Center
Helmholtz Head Office
Branch of a Helmholtz center
4
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Helmholtz-Zentrum Geesthacht
860 staff (incl. 281 scientists/128 guest scientists
+ 127 ongoing PhD thesis)
3 Research institutes, 8 Directors of institutes
81 Mio total budget (2007),
13,5 Mio 3rd-party (incl. industry)
271 ISI publications (2007)
> 50 apprentices
From application-
oriented
fundamental
research to
innovation
Teltow
Geesthacht
5
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Est. in 1992
Scientific and Technical Staff in 2011: about 30
fellows
Competence Areas of Research
FSW Process
Residual Stress & Distortion
Friction-based J oining Processes
Polymer-Metal J oining
Hybrid Solid State Processes
Metallurgy of Welding
Solid-State Joining Processes
Department (WMP)
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Workgroup Group @ HZG
- Students: 1 Postdoc, 3 PhD, 4 MSc and 1 undergraduationstudents
Integrated in the Institute of Polymer Composites at Hamburg
University of Technology (TUHH) through an Assistant Professorship
in Joining of Polymer-Metal Hybrid Structures
+ +
=
Advanced Polymer-Metal
Hybrid Structures Group
7
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Process development
Properties of the interface (bonding mechanisms)
Mechanical, physical-chemical, thermal and microstructural properties
of polymer composites / lightweight metal hybrid structures
R&D Strategy
J OINING TECHNOLOGY
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9
Car Manufacturers
Suppliers:
Material Supplier
Network of Partners
in the Automotive Sector
PAGE 9
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10
Challenges and Motivation
PAGE 10
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Challenges in Joining
Polymer to Metals and Composites
Physical-chemical dissimilarity
- Different Cohesion and Surface Energies. Low
miscibility!
- Difference in Coefficient of Thermal Expansion
and Heat Capacity can lead to separation
distortion of parts
- Reduced Thermal Resistance of the polymer
can lead to thermal degradation
For composites
- Avoid damage or modification of the network of
fibres
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Motivation
CFK
Magnesium
Increased use of polymer-metal hybrid structures in the engineering
applications (weight reduction and decrease in CO
2
emissions )
Available joining methods for those structures are either complex,
expensive or not environmental friendly
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J oining Technologies for Polymer-Metal Hybrid Structures
(S. Amancio and J .F. dos Santos, Polym. Eng. Sci., 2008)
State of the Art
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Friction Riveting
(FricRiveting)
PAGE 14
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Blaga 02.04.2012
15
FricRiveting is a innovative spot joining
technique for polymer-metal structures
(US Patent US 7 525 149 B2 (2009))
Based on mechanical fastening and
friction welding
Cylindrical metallic rivet is used to join
thermoplastic components
Prize-winning joining technology:
RSM 400 Friction Welding (Harms & Wende GmbH)
Friction Riveting - FricRiveting
- Spindel: RSM 400
- Rotational Speed: max. 23000 rpm
- Nominal Power: 1,8 kW
- Axial Force: max. 6 kN ( 10 bar)
- Granjon Prize 2009
- Nordmetall Preis 2008, Germany
- SPE-ANTEC 2008, USA
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FricRiveting
Positioning
of the
Partners
Rotating Rivet
Insertion &
Polymer Melting
Plasticizing
of the Rivet
& Forging
Anchoring of the
forged rivet &
J oint
Consolidation
Time
Principles of the process
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17 17
Microstructure: PEI / Al 2024
Polymer-Polymer Interface
Metal-Polymer
Interface
(adhesion)
PAGE 17
FricRiveting
TMAZ: DRX- grains
Base
Material
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Blaga 02.04.2012
18
Results and Discussions
5.65
3.50
4 mm
5.30
4.80
Glass fiber woven is shifted to about 45 degrees to the
upper face of the composite
Fiber network remains in contact with the rivet shaft
Reduced amount of thermal flaws
4 mm
Ti alloy / GFR PEI: Microstructure
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Al 2024 / PEI :Tensile Strength (Avg. Curve of 5 Samples)
PAGE 19
F
max
= 9,7 0,7 kN

Joint Strength Rivet

Strength
FricRiveting
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20
FricRiveting
v
v
Smaller Plunge Depth (heat input)
Larger Plunge Depth (heat input)
L. Blaga, S.T. Amancio-Filho et al. ANTEC 2012
Ti alloy / GFR PEI :Tensile
strength
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Al 2024 / PEI : Lap Shear Strength (avg. of 5 samples, ASTM D5961)
R
m
= 77,5 0,1 MPa

Shear Strength 70% of

PEI plaque
PAGE 21
FricRiveting
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Blaga 02.04.2012
22
Current Developments
Lap-shear specimen
Avg. lap shear strength of 200 MPa
Failure through shear of the metallic rivet
Friction riveted have similar behavior and
mechanical performance as bolted joints!
Ti alloy / GFR PEI : Lap Shear Strength (ASTM D5961)
Bolted specimen
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Current Investigations
FricRiveting
Medical Polymers / Ti alloys
(HZG-CCDM)
Automotive Plastics / Al alloys
(C. Rodrigues, MSc-Thesis)
1000 2000 3000 4000 5000 6000 7000 8000 9000
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2000
3000
4000
5000
6000
7000
8000
9000
Experimental
Validation
P
r
e
d
i
c
t
i
o
n
Experimental
1000 2000 3000 4000 5000 6000 7000 8000 9000
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Current Investigations
FricRiveting
Modelling of Mech. Properties
(M. Borges, MSc-Thesis)
GFRP / Ti alloys
(L. Blaga, Postdoc)
Temperature Modelling
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Friction Spot Welding
of Thermoplastics
PAGE 25
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- Developed and patented by HZG
(US Patent No. 6722556B2)
- Refilled Spot (no keyhole in the
welding region)
- For both metals and polymers,
FSpWshows better mechanical
properties than FSSW
- Similar or better mechanical
performance in comparison to other
spot welding techniques
1
1
P. Oliveira, S. Amancio-Filho, J . dos Santos, E. Hage J r., Mater. Lett., 64, 2098-101 (2010)
Principles
Friction Spot Welding
RSM 100 (Harms & Wende GmbH)
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Friction Spot Welding
Principles
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Weld Line
J oel Gonalves 10.02.12
Breaking and
reorientation of
the fibers
FSpW of PA 66-CF - Microstructure
Structure of the
CF laminate
Broken Fibers
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Rotation
(rpm)
Plunge
Depth(mm)
Plunge
Time (s)
Retracting
Time (s)
Pressure
(bar)
Holding Force
Time(s)
3000 2,2 2,3 4,5 3,0 20
Surface Finishing
Fracture Surface
U
p
p
e
r
L
o
w
e
r
Upper Lower
FSpW of PA 66-CF Mech. Properties
Mechanical Properties
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Current Investigations
Friction Stir /Stir Spot Welding
and FSpW of PMMA
(P. Oliveira, MSc-Thesis)
Friction Spot Welding of
PA 6 / PA66-CF
(J . Gonalves, MSc-Thesis)
Friction-based Spot Welding of
Thermoplastics / CRFP
PA6
PA6
PA6
PA66-CF
PA66-CF
PA66-CF
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Friction Spot Joining
of
Metal-Composite Structures
PAGE 31
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European Pat. Appl. EP 09015014
Shallow tool plunges (0,2-0,3 mm)
Metallic material is heated up and formed locally
J oint achieved by adhesion forces (consolidated polymer) and
mechanical interlocking (metallic nub)
Distinction Prize (Sonderwrdigung), 2011
Friction Spot Joining of
Composite-Metal Joints
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claded aluminium layer
Cross sectional viewof the joining partners
S. Goushegir, S.T. Amancio-Filho HZG, 2011
Alclad 2024-T3 / PPS-CF
Microstructure
Friction Spot Joining of
Composite-Metal Joints
claded aluminium layer
fibers covered by the
claded aluminiumlayer
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fibers attached to the
aluminiumsurface
Avg. lap shear resistance (ASTM
D352896) :
2570 N (40 MPa)
(surface treatment: grit paper P1200)
10 mm
10 mm
Friction Spot Joining of
Composite-Metal Joints
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Mechanical Performance of FSp Joints
Attempt to evaluate current strength of FSpJ
with state-of-the-art joining technologies:
- Similar geometries and failure mechanisms
- Different base materials
35
A
l

5
7
5
4
A
Z

3
1
A
l

6
1
8
1
5
4

M
P
a
4
0

M
P
a

(

A
l

2
0
2
4
)
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Current Investigations
Friction Spot Joining of
Composite-Metal Joints
Al 5754 / CFRP
(T. Rocha, Dipl. -Thesis)
Al-CFRP Double Lap Joints
(J . Esteves, MSc-Thesis)
AZ31 - Composite Interface
Properties
(C.Bueno, Dipl. Thesis)
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Injection Clinching Joining
(ICJ)
PAGE 37
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Newspot joining process for thermoplastics and metals (HZG
Patent, DE 10 2005 057 891.8 2005)
Based on principles from injection moulding, adhesive
bonding and staking
Tooling: Electrical Heating and Frictional Heating
Prize of PPS-2010 Banff, Canada
Injection Clinching Joining (ICJ)
X
Frictional heating Electrical heating
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Electrical Heating ICJ
Main parameters: heating time and heating
temperature
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ABIBE, A.B et al., J Thermop Comp Mat, 2011
Polymer
Metal
Electrical Heating ICJ
Excellent mechanical performance
Better cavity filling results in higher
global
Mechanical properties
Limitations: long joining times and
high energy consumption
88,5%
35,9%
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Friction-based ICJ
Energy efficient
Faster cycles
Simpler tooling
Main Parameters
- Rotational speed
- J oining time
- J oining pressure
41
Equipment: RSM400
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PA66 30%GF / Al 2024( Process duration: 3s -5s)
PA66-FG30%
AA2024-T351
Friction-based ICJ
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Advantages
Little or absent surface cleaning /
preparation.
Easy accessibility
J oining is independent of position.
Short joining cycles (0,5 to 10 s)
A wide range of materials and can be
joined
Hermetic sealed joints
Simple and low cost machinery.
Robotic application is also possible
J oints with good tensile and shear
performance
Limitations
Only spot-like joints
Not applicable for thermoset polymers,
without selecting optimized joint
geometries
non-reopenable joints
Minimum thickness of the polymeric
partner(s). Nevertheless, this can be
reduced by altering geometry of joint
Tool wear in FSpW of CFRP
(not in FSpJ !!!)
PAGE 43
Advantages & Limitations
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J oinability of Polymer-Metal structures is stronglydependent on the
level of properties dissimilarity
Solid-State J oining Processes are innovative technologies for
environmental friendly and cost effective lightweight design
The know-howin Polymer-Metal J oining is an asset for the
increasing market competition in the field of multi-material
lightweight design
Final Remarks
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PAGE 45
Potential Applications ?
Alternative processes to adhesively bonded, riveted and bolted joints?
Adequate for joints between TPO and Engineering Plastics and
Composites (FricRiveting)
As local reinforcement for bonded structures (FSpJ )?
As alternative to currently available spot welding (FSpW)
Input / Feedback from the Automotive Engineering Community!
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Financial Support
Acknowledgements
46
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Prof. Dr.-Ing. Sergio Amancio
E-mail: sergio.amancio@hzg.de
Tel.: +49 4152 872066
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