Professional Documents
Culture Documents
Innovative Solid-State Spot Joining Methods For Fiber Composites and Metal-Polymer Hybrid Structures
Innovative Solid-State Spot Joining Methods For Fiber Composites and Metal-Polymer Hybrid Structures
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
Bremerhaven
Geesthacht
Hamburg
GreifswaId
Braunschweig
WoIfenbtteI-
RemIingen
Gttingen
Magdeburg
Potsdam
BerIin
Zeuthen
TeI tow
Niemegk
HaIIe
Leipzig
Bad
Lauchstdt
KIn
JIich
Bonn
Darmstadt
HeideIberg
LampoIdshausen
KarIsruhe
Stuttgart
Mnchen
Garching Neuherberg
Oberpfaffenhofen
Helmholtz Center
Helmholtz Head Office
Branch of a Helmholtz center
4
Amanci o, 18.04.12 5
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
Amanci o, 18.04.12 6
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)
Amanci o, 18.04.12 7
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
Amanci o, 18.04.12 9
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
Amanci o, 18.04.12 14
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