Joining of additively manufactured fiber-reinforced thermoplastic and metals by ultrasonic energy: Mechanical and corrosion behavior
Ultrasonic joining (U-Joining) is applied to create reinforced hybrid joints between unreinforced or fiber-reinforced polymers and surface-structured metals. While the feasibility of joining additively manufactured (AM) materials was already demonstrated, a detailed description of the process parame...
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| Format: | Article |
| Language: | English |
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Elsevier
2023-10-01
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| Series: | Materials & Design |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S0264127523007578 |
| _version_ | 1797647901893066752 |
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| author | Willian S. de Carvalho Guilherme S. Vacchi Carlos A.D. Rovere Sergio T. Amancio-Filho |
| author_facet | Willian S. de Carvalho Guilherme S. Vacchi Carlos A.D. Rovere Sergio T. Amancio-Filho |
| author_sort | Willian S. de Carvalho |
| collection | DOAJ |
| description | Ultrasonic joining (U-Joining) is applied to create reinforced hybrid joints between unreinforced or fiber-reinforced polymers and surface-structured metals. While the feasibility of joining additively manufactured (AM) materials was already demonstrated, a detailed description of the process parameters’ effects is still missing. Therefore, this study aims to define the influence of the U-Joining parameters on the mechanical and corrosion properties of AM 20% short-carbon-fiber-reinforced poly-ether-ether-ketone (PEEK-20CF) and 316L stainless steel (316L SS) hybrid joints. Optimal joining parameters were determined via Box-Behnken design of experiments to maximize the joints’ ultimate lap shear forces (ULSF) and displacement at break (DaB), where the results increased from 1.4 ± 0.2 kN to 3.6 ± 0.3 kN (2.6 times) and from 1.2 ± 0.3 mm to 2.4 ± 0.1 mm (2 times), respectively. Microstructural analyses revealed a strong micromechanical interlocking between the parts due to the filling of crevices at the as-built AM metallic part’s rough surface by consolidated PEEK-20CF, which resulted in a mixture of adhesive, cohesive and net tension failure during the lap-shear tests. Finally, the corrosion resistance was also evaluated by potentiodynamic polarization curves, showing that the energy input during the joining cycle slightly reduced the pitting corrosion resistance of the 316L part. |
| first_indexed | 2024-03-11T15:24:24Z |
| format | Article |
| id | doaj.art-92c72910fbc2463eb3aef0d5d460f323 |
| institution | Directory Open Access Journal |
| issn | 0264-1275 |
| language | English |
| last_indexed | 2024-03-11T15:24:24Z |
| publishDate | 2023-10-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Materials & Design |
| spelling | doaj.art-92c72910fbc2463eb3aef0d5d460f3232023-10-28T05:06:33ZengElsevierMaterials & Design0264-12752023-10-01234112342Joining of additively manufactured fiber-reinforced thermoplastic and metals by ultrasonic energy: Mechanical and corrosion behaviorWillian S. de Carvalho0Guilherme S. Vacchi1Carlos A.D. Rovere2Sergio T. Amancio-Filho3Graz University of Technology – TU Graz, Institute of Materials Science, Joining and Forming, BMK Endowed Professorship for Aviation, Kopernikusgasse 24/1, 8010 Graz – Austria; Corresponding authors.Federal University of São Carlos – UFSCar, Department of Materials Engineering, Rodovia Washington Luis Km 235, 13565-905 São Carlos, SP, BrazilFederal University of São Carlos – UFSCar, Department of Materials Engineering, Rodovia Washington Luis Km 235, 13565-905 São Carlos, SP, BrazilGraz University of Technology – TU Graz, Institute of Materials Science, Joining and Forming, BMK Endowed Professorship for Aviation, Kopernikusgasse 24/1, 8010 Graz – Austria; Corresponding authors.Ultrasonic joining (U-Joining) is applied to create reinforced hybrid joints between unreinforced or fiber-reinforced polymers and surface-structured metals. While the feasibility of joining additively manufactured (AM) materials was already demonstrated, a detailed description of the process parameters’ effects is still missing. Therefore, this study aims to define the influence of the U-Joining parameters on the mechanical and corrosion properties of AM 20% short-carbon-fiber-reinforced poly-ether-ether-ketone (PEEK-20CF) and 316L stainless steel (316L SS) hybrid joints. Optimal joining parameters were determined via Box-Behnken design of experiments to maximize the joints’ ultimate lap shear forces (ULSF) and displacement at break (DaB), where the results increased from 1.4 ± 0.2 kN to 3.6 ± 0.3 kN (2.6 times) and from 1.2 ± 0.3 mm to 2.4 ± 0.1 mm (2 times), respectively. Microstructural analyses revealed a strong micromechanical interlocking between the parts due to the filling of crevices at the as-built AM metallic part’s rough surface by consolidated PEEK-20CF, which resulted in a mixture of adhesive, cohesive and net tension failure during the lap-shear tests. Finally, the corrosion resistance was also evaluated by potentiodynamic polarization curves, showing that the energy input during the joining cycle slightly reduced the pitting corrosion resistance of the 316L part.http://www.sciencedirect.com/science/article/pii/S0264127523007578Ultrasonic joiningHybrid structuresProcess optimizationAdditive manufacturingFused filament fabricationLaser powder bed fusion |
| spellingShingle | Willian S. de Carvalho Guilherme S. Vacchi Carlos A.D. Rovere Sergio T. Amancio-Filho Joining of additively manufactured fiber-reinforced thermoplastic and metals by ultrasonic energy: Mechanical and corrosion behavior Materials & Design Ultrasonic joining Hybrid structures Process optimization Additive manufacturing Fused filament fabrication Laser powder bed fusion |
| title | Joining of additively manufactured fiber-reinforced thermoplastic and metals by ultrasonic energy: Mechanical and corrosion behavior |
| title_full | Joining of additively manufactured fiber-reinforced thermoplastic and metals by ultrasonic energy: Mechanical and corrosion behavior |
| title_fullStr | Joining of additively manufactured fiber-reinforced thermoplastic and metals by ultrasonic energy: Mechanical and corrosion behavior |
| title_full_unstemmed | Joining of additively manufactured fiber-reinforced thermoplastic and metals by ultrasonic energy: Mechanical and corrosion behavior |
| title_short | Joining of additively manufactured fiber-reinforced thermoplastic and metals by ultrasonic energy: Mechanical and corrosion behavior |
| title_sort | joining of additively manufactured fiber reinforced thermoplastic and metals by ultrasonic energy mechanical and corrosion behavior |
| topic | Ultrasonic joining Hybrid structures Process optimization Additive manufacturing Fused filament fabrication Laser powder bed fusion |
| url | http://www.sciencedirect.com/science/article/pii/S0264127523007578 |
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