workshop 3 amanico

8/13/2019 Workshop 3 Amanico

1/47

Joining in Car Body 2012, Bad Nauheim, 18.04.2012

Innovative solid-state spot joining methodsfor 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


2/47

Amancio, 18.04.12 2

Contents

Introduction

Challenges and Motivation

Friction Riveting

Friction Spot Welding / Joining

ICJ Method

Final Remarks


3/47

Amancio, 18.04.12 3

Introduction

PAGE 3


4/47Amancio, 18.04.12 4PAGE 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

Bremerhaven GeesthachtHamburg

Greifswald

Braunschweig

Wolfenbttel-

Remlingen

Gttingen

Magdeburg

Potsdam

Berlin

ZeuthenTel tow

Niemegk

Halle

LeipzigBad

LauchstdtKln

Jlich

Bonn

Darmstadt

Heidelberg

Lampoldshausen

Karlsruhe

Stuttgart

Mnchen

GarchingNeuherberg

Oberpfaffenhofen

Helmholtz Center

Helmholtz Head Office

Branch of a Helmholtz center

4


5/47Amancio, 18.04.12 5

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-

orientedfundamentalresearch to

innovation

Teltow

Geesthacht

5


6/47Amancio, 18.04.12 6 6

Est. in 1992

Scientific and Technical Staff in 2011: about 30

fellows

Competence Areas of Research

FSW Process

Residual Stress & Distortion

Friction-based Joining Processes

Polymer-Metal Joining

Hybrid Solid State Processes

Metallurgy of Welding

Solid-State Joining Processes

Department (WMP)


7/47Amancio, 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 anAssistant Professorship

in Joining of Polymer-Metal Hybrid Structures

++ =

Advanced Polymer-Metal

Hybrid Structures Group

7


8/47Amancio, 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


9/47Amancio, 18.04.12 9

Car Manufacturers

Suppliers:

Material Supplier

Network of Partners

in the Automotive Sector

PAGE 9


10/47

Amancio, 18.04.12 10

Challenges and Motivation

PAGE 10


11/47


12/47


13/47

Amancio, 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


14/47

Amancio, 18.04.12 14

Friction Riveting

(FricRiveting)

PAGE 14


15/47

Amancio, 18.04.12 15Blaga 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 jointhermoplastic 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


16/47

Amancio, 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


17/47


18/47

Amancio, 18.04.12 18Blaga 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


19/47

Amancio, 18.04.12 1919

Al 2024 / PEI :Tensile Strength (Avg. Curve of 5 Samples)

PAGE 19

Fmax= 9,7 0,7 kNJoint Strength Rivet

Strength

FricRiveting


20/47

Amancio, 18.04.12 2020 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 :Tensilestrength


21/47

Amancio, 18.04.12 2121

Al 2024 / PEI : Lap Shear Strength (avg. of 5 samples, ASTM D5961)

Rm= 77,5 0,1 MPaShear Strength 70% of

PEI plaquePAGE 21

FricRiveting


22/47

Amancio, 18.04.12 22Blaga 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


23/47

Amancio, 18.04.12 23 23

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

1000

2000

3000

4000

5000

6000

7000

8000

9000 ExperimentalValidation

Prediction

Experimental

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


24/47

Amancio, 18.04.12 24 24

Current Investigations

FricRiveting

Modelling of Mech. Properties(M. Borges, MSc-Thesis)

GFRP / Ti alloys(L. Blaga, Postdoc)

Temperature Modelling


25/47

Amancio, 18.04.12 25

Friction Spot Welding

of Thermoplastics

PAGE 25


26/47

S


27/47

Amancio, 18.04.12 27

Friction Spot Welding

Principles

FS W f PA 66 CF Mi t t


28/47

Amancio, 18.04.12 2828

Weld Line

Joel Gonalves 10.02.12

Breaking and

reorientation of

the fibers

FSpW of PA 66-CF - Microstructure

Structure of the

CF laminate

Broken Fibers

FS W f PA 66 CF M h P ti


29/47

Amancio, 18.04.12 2929

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

Upp

er

Lower

Upper Lower

FSpW of PA 66-CF Mech. Properties

Mechanical Properties

Friction-based Spot Welding of


30/47

Amancio, 18.04.12 30

Current InvestigationsFriction Stir /Stir Spot Welding

and FSpW of PMMA

(P. Oliveira, MSc-Thesis)

Friction Spot Welding ofPA 6 / PA66-CF

(J. Gonalves, MSc-Thesis)

Friction based Spot Welding of

Thermoplastics / CRFP

PA6

PA6

PA6

PA66-CF

PA66-CF

PA66-CF


31/47

Amancio, 18.04.12 31

Friction Spot Joining

of

Metal-Composite Structures

PAGE 31

Friction Spot Joining of


32/47

Amancio, 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


Composite-Metal Joints



33/47

Amancio, 18.04.12 3333

claded aluminium layer

Cross sectional view of the joining partners

S. Goushegir, S.T. Amancio-Filho HZG, 2011

Alclad 2024-T3 / PPS-CF

Microstructure

p g



fibers covered by the




34/47

Amancio, 18.04.12 3434

fibers attached to the

aluminium surface

Avg. lap shear resistance (ASTM

D352896) :

2570 N (40 MPa)

(surface treatment: grit paper P1200)

10 mm

10 mm

p g


Mechanical Performance of FSp Joints


35/47

Amancio, 18.04.12 35

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

Al5754

AZ31

Al6181

54MPa

40MPa(Al2024)


36/47


37/47

Amancio, 18.04.12 37

Injection Clinching Joining

(ICJ)

PAGE 37

Injection Clinching Joining (ICJ)


38/47

Amancio, 18.04.12 3838

New spot joining process for thermoplastics and metals (HZG

Patent, DE 10 2005 057 891.8 2005)

Based on principles from injection moulding, adhesivebonding and staking

Tooling: Electrical Heating and Frictional Heating

Prize of PPS-2010 Banff, Canada

Injection Clinching Joining (ICJ)

X

Frictional heatingElectrical heating


39/47


40/47

Friction based ICJ


41/47

Amancio, 18.04.12 4141

Friction-based ICJ

Energy efficient

Faster cycles

Simpler tooling

Main Parameters

- Rotational speed

- Joining time

- Joining pressure

41

Equipment: RSM400


42/47

Advantages & Limitations


43/47

Amancio, 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 bejoined

Hermetic sealed joints

Simple and low cost machinery.Robotic application is also possible

Joints with good tensile and shearperformance

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

Final Remarks


44/47

Amancio, 18.04.12 4444

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-materiallightweight design

Potential Applications ?


45/47

Amancio, 18.04.12 45PAGE 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!


46/47


47/47

workshop 3 amanico

Documents