Joining in Car Body 2012, Bad Nauheim, 18.04.

2012
Innovative soIid-state spot joining methods
for fiber composites and metaI-poIymer
hybrid structures
Prof. Dr.-Ing. Sergio Amancio
Institute of MateriaIs Research - MateriaIs Mechanics
SoIid State Joining Processes (WMP)
"Advanced PoIymer-MetaI Hybrid Structures" Group
Amanci o, 18.04.12 2
Contents
Introduction
Challenges and Motivation
Friction Riveting
Friction Spot Welding / Joining
ICJ Method
Final Remarks
Amanci o, 18.04.12 3
Introduction
PAGE 3
Amanci o, 18.04.12 4 PAGE 4
HeImhoItz 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 biIIion C
List
HeIgoIand
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Helmholtz Head Office
Branch of a Helmholtz center
4
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HeImhoItz-Zentrum Geesthacht
860 staff (incI. 281 scientists/128 guest scientists
+ 127 ongoing PhD thesis)
3 Research institutes, 8 Directors of institutes
81 Mio C totaI budget (2007),
13,5 Mio C 3rd-party (incI. industry)
271 ISI pubIications (2007)
> 50 apprentices
From appIication-
oriented
fundamentaI
research to
innovation
TeItow
Geesthacht
5
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6
Est. in 1992
Scientific and TechnicaI Staff in 2011: about 30
feIIows
Competence Areas of Research
FSW Process
Residual Stress & Distortion
Friction-based Joining Processes
Polymer-Metal Joining
Hybrid Solid State Processes
Metallurgy of Welding
SoIid-State Joining Processes
Department (WMP)
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Workgroup Group @ HZG
- Students: 1 Postdoc, 3 PhD, 4 MSc and 1 undergraduation students
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 PoIymer-MetaI
Hybrid Structures" Group
7
Amanci o, 18.04.12 8
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
JOINING TECHNOLOGY
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Car Manufacturers
Suppliers:
Material Supplier
Network of Partners
in the Automotive Sector
PAGE 9
Amanci o, 18.04.12 10
ChaIIenges and Motivation
PAGE 10
Amanci o, 18.04.12 11
ChaIIenges in Joining
PoIymer to MetaIs and Composites
PhysicaI-chemicaI dissimiIarity
- 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
Amanci o, 18.04.12 12
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
Amanci o, 18.04.12 13
Joining 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
Amanci o, 18.04.12 15 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 WeIding (Harms & Wende GmbH)
Friction Riveting - FricRiveting
- SpindeI: RSM 400
- RotationaI Speed: max. 23000 rpm
- NominaI Power: 1,8 kW
- AxiaI Force: max. 6 kN ( 10 bar)
- Granjon Prize 2009
- Nordmetall Preis 2008, Germany
- SPE-ANTEC 2008, USA
Amanci o, 18.04.12 16
16
FricRiveting
Positioning
of the
Partners
Rotating Rivet
Insertion &
Polymer Melting
Plasticizing
of the Rivet
& Forging
Anchoring of the
forged rivet &
Joint
Consolidation
Time
Principles of the process
Amanci o, 18.04.12 17 17
Microstructure: PEI / Al 2024
Polymer-Polymer Interface
Metal-Polymer
Interface
(adhesion)
PAGE 17
FricRiveting
TMAZ: DRX- grains
Base
Material
Amanci o, 18.04.12 18 Blaga 02.04.2012 18
ResuIts 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
Amanci o, 18.04.12 19 19
Al 2024 / PEI :Tensile Strength (Avg. Curve of 5 Samples)
PAGE 19
F
max
= 9,7 0,7 kN

Joint Strength Rivet

Strength
FricRiveting
Amanci o, 18.04.12 20 20
20
FricRiveting
v
v
SmaIIer PIunge Depth (heat input)
Larger PIunge Depth (heat input)
L. Blaga, S.T. Amancio-Filho et al. ANTEC 2012
Ti alloy / GFR PEI :Tensile
strength
Amanci o, 18.04.12 21 21
Al 2024 / PEI : Lap Shear Strength (avg. of 5 samples, ASTM D5961)
R
m
= 77,5 0,1 MPa

Shear Strength 70% of

PEI pIaque
PAGE 21
FricRiveting
Amanci o, 18.04.12 22 Blaga 02.04.2012 22
Current DeveIopments
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)
BoIted specimen
Amanci o, 18.04.12 23
23
Current Investigations
FricRiveting
MedicaI PoIymers / Ti aIIoys
(HZG-CCDM)
Automotive PIastics / AI aIIoys
(C. Rodrigues, MSc-Thesis)
1000 2000 3000 4000 5000 6000 7000 8000 9000
1000
2000
3000
4000
5000
6000
7000
8000
9000
Experi mental
Validation
P
r
e
d
ic
t
io
n
Experi mental
1000 2000 3000 4000 5000 6000 7000 8000 9000
1000
2000
3000
4000
5000
6000
7000
8000
9000
1000 2000 3000 4000 5000 6000 7000 8000 9000
1000
2000
3000
4000
5000
6000
7000
8000
9000
1000 2000 3000 4000 5000 6000 7000 8000 9000
1000
2000
3000
4000
5000
6000
7000
8000
9000



Amanci o, 18.04.12 24
24
Current Investigations
FricRiveting
ModeIIing of Mech. Properties
(M. Borges, MSc-Thesis)
GFRP / Ti aIIoys
(L. Blaga, Postdoc)
Temperature ModeIIing
Amanci o, 18.04.12 25
Friction Spot WeIding
of ThermopIastics
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 Sant os, E. Hage Jr., Mater. Lett., 64, 2098-101 (2010)
PrincipIes
Friction Spot WeIding
RSM 100 (Harms & Wende GmbH)
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Friction Spot WeIding
Principles
Amanci o, 18.04.12 28 28
WeId Line
Joel Gonal ves 10.02.12
Breaking and
reorientation of
the fibers
FSpW of PA 66-CF - Microstructure
Structure of the
CF Iaminate
Broken Fibers
Amanci o, 18.04.12 29 29
Rotation
(rpm)
PIunge
Depth(mm)
PIunge
Time (s)
Retracting
Time (s)
Pressure
(bar)
HoIding 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
MechanicaI Properties
Amanci o, 18.04.12 30
Current Investigations
Friction Stir /Stir Spot WeIding
and FSpW of PMMA
(P. Oliveira, MSc-Thesis)
Friction Spot WeIding of
PA 6 / PA66-CF
(J. Gonalves, MSc-Thesis)
Friction-based Spot WeIding of
ThermopIastics / CRFP
PA6
PA6
PA6
PA66-CF
PA66-CF
PA66-CF
Amanci o, 18.04.12 31
Friction Spot Joining
of
MetaI-Composite Structures
PAGE 31
Amanci o, 18.04.12 32
European Pat. Appl. EP 09015014
Shallow tool plunges (0,2-0,3 mm)
Metallic material is heated up and formed locally
Joint achieved by adhesion forces (consolidated polymer) and
mechanical interlocking (metallic nub)
Distinction Prize (Sonderwrdigung), 2011
Friction Spot Joining of
Composite-MetaI Joints
Amanci o, 18.04.12 33 33
cIaded aIuminium Iayer
Cross sectionaI viewof the joining partners
S. Goushegir, S.T. Amancio-Filho HZG, 2011
Alclad 2024-T3 / PPS-CF
Microstructure
Friction Spot Joining of
Composite-MetaI Joints
cIaded aIuminium Iayer
fibers covered by the
cIaded aIuminium Iayer
Amanci o, 18.04.12 34 34
fibers attached to the
aIuminium surface
Avg. lap shear resistance (ASTM
D352896) :
2570 N (40 MPa)
(surface treatment: grit paper P1200)
10 mm
10 mm
Friction Spot Joining of
Composite-MetaI Joints
Amanci o, 18.04.12 35
MechanicaI 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
I

5
7
5
4
A
Z

3
1
A
I

6
1
8
1
5
4

M
P
a
4
0

M
P
a

(

A
I

2
0
2
4
)
Amanci o, 18.04.12 36
Current Investigations
Friction Spot Joining of
Composite-MetaI Joints
AI 5754 / CFRP
(T. Rocha, Dipl. -Thesis)
AI-CFRP DoubIe Lap Joints
(J. Esteves, MSc-Thesis)
AZ31 - Composite Interface
Properties
(C.Bueno, Dipl. Thesis)
Amanci o, 18.04.12 37
Injection CIinching Joining
(ICJ)
PAGE 37
Amanci o, 18.04.12 38 38
New spot 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 CIinching Joining (ICJ)
!
Frictional heating Electrical heating
Amanci o, 18.04.12 39 39 39
EIectricaI Heating ICJ
Main parameters: heating time and heating
temperature
Amanci o, 18.04.12 40 40 40
ABIBE, A.B et al ., J Thermop Comp Mat, 2011
Polymer
Metal
EIectricaI 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%
Amanci o, 18.04.12 41 41
Friction-based ICJ
Energy efficient
Faster cycles
Simpler tooling
Main Parameters
- Rotational speed
- Joining time
- Joining pressure
41
Equipment: RSM400
Amanci o, 18.04.12 42 42
PA66 30%GF / Al 2024 ( Process duration: 3s -5s)
PA66-FG30%
AA2024-T351
Friction-based ICJ
Amanci o, 18.04.12 43
Advantages
Little or absent surface cleaning /
preparation.
Easy accessibility
Joining 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
Joints 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
Amanci o, 18.04.12 44 44
Joinability of Polymer-Metal structures is strongly dependent on the
level of properties dissimilarity
Solid-State Joining Processes are innovative technologies for
environmental friendly and cost effective lightweight design
The know-how in Polymer-Metal Joining is an asset for the
increasing market competition in the field of multi-material
lightweight design
FinaI Remarks
Amanci o, 18.04.12 45 PAGE 45
PotentiaI AppIications ?
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!
Amanci o, 18.04.12 46
Financial Support
AcknowIedgements
46
Amanci o, 18.04.12 47 47
Prof. Dr.-Ing. Sergio Amancio
E-mail: sergio.amancio@hzg.de
Tel.: +49 4152 872066
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