Effects of welding parameters and thermal insulation on the mechanical behavior and microstructure of friction lap-welded aluminum to glass fiber–reinforced thermoset composite with a thermoplastic PA6 interlayer

IF 2.9 3区 工程技术 Q2 AUTOMATION & CONTROL SYSTEMS
Mahdi Sahranavard, Hadi Khoramishad
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Abstract

Friction lap welding was used to join aluminum with glass fiber–reinforced thermoset polymer (GFRP) using a thermoplastic interlayer. The effect of different welding parameters on joint strength and fracture surfaces was investigated, and the optimal welding parameters were determined using the Taguchi method. Results revealed that low heat generation led to weak mechanical interlocking between GFRP and the thermoplastic interlayer, while high heat generation caused degradation of the aluminum/thermoplastic polymer interface. The tool traverse speed was found to be the most influential parameter in terms of joint strength, followed by plunge depth and rotational speed. Moreover, thermal measurements were conducted during the welding process using thermocouples. An uneven thermal distribution was discovered across the overlap area due to dissimilar substrates. This issue was resolved by incorporating aluminum thermal insulation, resulting in improved heat distribution and a significant enhancement of 94% in joint strength. Scanning electron microscopy (SEM) was employed to identify joining mechanisms and examine the effect of welding parameters on joint microstructure. Furthermore, Fourier-transform infrared spectroscopy (FTIR) was used to investigate chemical bond formation at the aluminum/thermoplastic polymer interface. The results showed that the joining mechanisms involved mechanical interlocking between the thermoplastic interlayer and aluminum, as well as chemical bonding, penetration, and intertwining between the thermoplastic interlayer and the thermoset composite.

Abstract Image

焊接参数和隔热材料对带有热塑性 PA6 中间层的铝与玻璃纤维增强热固性复合材料摩擦搭接焊的机械性能和微观结构的影响
采用摩擦搭接焊连接铝与玻璃纤维增强热固性聚合物(GFRP),并使用热塑性夹层。研究了不同焊接参数对接头强度和断裂面的影响,并采用田口方法确定了最佳焊接参数。结果表明,低发热量会导致 GFRP 和热塑性夹层之间的机械互锁性减弱,而高发热量则会导致铝/热塑性聚合物界面退化。研究发现,工具移动速度是对接合强度影响最大的参数,其次是切入深度和旋转速度。此外,在焊接过程中还使用热电偶进行了热测量。发现由于基材不同,重叠区域的热分布不均匀。通过采用铝隔热材料解决了这一问题,从而改善了热分布,并将接头强度显著提高了 94%。扫描电子显微镜(SEM)被用来确定接合机制,并检查焊接参数对接合微观结构的影响。此外,还使用傅立叶变换红外光谱(FTIR)来研究铝/热塑性聚合物界面上化学键的形成。结果表明,接合机制包括热塑性夹层和铝之间的机械互锁,以及热塑性夹层和热固性复合材料之间的化学键合、渗透和交织。
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来源期刊
CiteScore
5.70
自引率
17.60%
发文量
2008
审稿时长
62 days
期刊介绍: The International Journal of Advanced Manufacturing Technology bridges the gap between pure research journals and the more practical publications on advanced manufacturing and systems. It therefore provides an outstanding forum for papers covering applications-based research topics relevant to manufacturing processes, machines and process integration.
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