Skip to main content

Advertisement

SpringerLink
Log in

Feasibility of friction stir joining of polycarbonate to CFRP with thermosetting matrix

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Friction stir joining (FSJ) process was preformed to produce hybrid joints between amorphous thermoplastic (polycarbonate) and carbon fiber-reinforced plastic (CFRP) with thermosetting matrix in lap configuration. The influence of the pin plunging depth (within the CFRP) and the tool shoulder plunging depth (within the polycarbonate) was studied to determine the suitability of FSJ process for these types of materials. Single-lap shear tests were conducted to determine the mechanical characteristics of the joints. Results indicated that the strength of the joints was significantly affected by the tool plunging depth, while it was marginally influenced by the tool shoulder plunging depth. The toughness of the joints is greatly influenced by the tool shoulder plunging depth. Morphological characterization and fracture surface analysis clarified the influence of these process parameters on the mechanical characteristics of the joints. The results from this study highlight the high mechanical properties of the joints (up to 12 MPa) due to the replacement of the original epoxy matrix of the composite by means of the polycarbonate.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

References

  1. Kumar R, Singh R, Ahuja IPS, Penna R, Feo L (2018) Weldability of thermoplastic materials for friction stir welding- a state of art review and future applications. Compos Part B 137:1–15

    Article  Google Scholar 

  2. Huang Y, Meng X, Xie Y, Wan L, Lv Z, Cao J, Feng J (2018) Friction stir welding/processing of polymers and polymer matrix composites. Compos A: Appl Sci Manuf 105:235–257

    Article  Google Scholar 

  3. F. Khodabakhshi, M.-. Haghshenas, J. Chen, B. Shalchi Amirkhiz, J. Li, A.P. Gerlich, Bonding mechanism and interface characterisation during dissimilar friction stir welding of an aluminium/polymer bi-material joint, Science and Technology of Welding and Joining, 22 (2017) 182–190

    Article  Google Scholar 

  4. Moshwan R, Rahmat SM, Yusof F, Hassan MA, Hamdi M, Fadzil M (2015) Dissimilar friction stir welding between polycarbonate and AA 7075 aluminum alloy. Int J Mater Res 106:258–266

    Article  Google Scholar 

  5. Huang Y, Meng X, Wang Y, Xie Y, Zhou L (2018) Joining of aluminum alloy and polymer via friction stir lap welding. J Mater Process Technol 257:148–154

    Article  Google Scholar 

  6. Huang Y, Meng X, Xie Y, Li J, Si X, Fan Q (2019) Improving mechanical properties of composite/metal friction stir lap welding joints via a taper-screwed pin with triple facets. J Mater Process Technol 268:80–86

    Article  Google Scholar 

  7. Derazkola HA, Simchi A (2019) An investigation on the dissimilar friction stir welding of T-joints between AA5754 aluminum alloy and poly(methyl methacrylate). Thin-Walled Struct 135:376–384

    Article  Google Scholar 

  8. Lionetto F, Balle F, Maffezzoli A (2017) Hybrid ultrasonic spot welding of aluminum to carbon fiber reinforced epoxy composites. J Mater Process Technol 247:289–295

    Article  Google Scholar 

  9. Lionetto F, Mele C, Leo P, D'Ostuni S, Balle F, Maffezzoli A (2018) Ultrasonic spot welding of carbon fiber reinforced epoxy composites to aluminum: mechanical and electrochemical characterization. Compos Part B 144:134–142

    Article  Google Scholar 

  10. Liu FC, Liao J, Nakata K (2014) Joining of metal to plastic using friction lap welding. Mater Des 54:236–244

    Article  Google Scholar 

  11. Nagatsuka K, Yoshida S, Tsuchiya A, Nakata K (2015) Direct joining of carbon-fiber–reinforced plastic to an aluminum alloy using friction lap joining. Compos Part B 73:82–88

    Article  Google Scholar 

  12. Wirth FX, Zaeh MF, Krutzlinger M, Silvanus J (2014) Analysis of the bonding behavior and joining mechanism during friction press joining of aluminum alloys with thermoplastics. Procedia CIRP 18:215–220

    Article  Google Scholar 

  13. Amancio-Filho ST, Bueno C, dos Santos JF, Huber N, Hage E (2011) On the feasibility of friction spot joining in magnesium/fiber-reinforced polymer composite hybrid structures. Mater Sci Eng A 528:3841–3848

    Article  Google Scholar 

  14. Yusof F, Miyashita Y, Seo N, Mutoh Y, Moshwan R (2013) Utilising friction spot joining for dissimilar joint between aluminium alloy (A5052) and polyethylene terephthalate. Sci Technol Weld Join 17:544–549

    Article  Google Scholar 

  15. Goushegir SM, dos Santos JF, Amancio-Filho ST (2015) Influence of process parameters on mechanical performance and bonding area of AA2024/carbon-fiber-reinforced poly(phenylene sulfide) friction spot single lap joints. Mater Des 83:431–442

    Article  Google Scholar 

  16. Esteves JV, Goushegir SM, dos Santos JF, Canto LB, Hage E, Amancio-Filho ST (2015) Friction spot joining of aluminum AA6181-T4 and carbon fiber-reinforced poly(phenylene sulfide): effects of process parameters on the microstructure and mechanical strength. Mater Des 66:437–445

    Article  Google Scholar 

  17. Yusof F, Muhamad M, Moshwan R, Jamaludin M, Miyashita Y (2016) Effect of surface states on joining mechanisms and mechanical properties of aluminum alloy (A5052) and polyethylene terephthalate (PET) by dissimilar friction spot welding. Metals 6:101

    Article  Google Scholar 

  18. Lambiase F, Paoletti A, Grossi V, Di Ilio A (2017) Friction assisted joining of aluminum and PVC sheets. J Manuf Process 29:221–231

    Article  Google Scholar 

  19. Lambiase F, Paoletti A, Grossi V, Genna S (2017) Improving energy efficiency in friction assisted joining of metals and polymers. J Mater Process Technol 250:379–389

    Article  Google Scholar 

  20. Lambiase F, Paoletti A (2018) Mechanical behavior of AA5053/polyetheretherketone (PEEK) made by friction assisted joining. Compos Struct 189:70–78

    Article  Google Scholar 

  21. Lambiase F, Paoletti A (2018) Friction assisted joining of titanium and polyetheretherketone (PEEK) sheets. Thin-Walled Struct 130:254–261

    Article  Google Scholar 

  22. Wahba M, Kawahito Y, Katayama S (2011) Laser direct joining of AZ91D thixomolded mg alloy and amorphous polyethylene terephthalate. J Mater Process Technol 211:1166–1174

    Article  Google Scholar 

  23. Jung KW, Kawahito Y, Takahashi M, Katayama S (2013) Laser direct joining of carbon fiber reinforced plastic to zinc-coated steel. Mater Des 47:179–188

    Article  Google Scholar 

  24. Tan X, Zhang J, Shan J, Yang S, Ren J (2015) Characteristics and formation mechanism of porosities in CFRP during laser joining of CFRP and steel. Compos Part B 70:35–43

    Article  Google Scholar 

  25. Yusof F, Yukio M, Yoshiharu M, Abdul Shukor MH (2012) Effect of anodizing on pulsed Nd:YAG laser joining of polyethylene terephthalate (PET) and aluminium alloy (A5052). Mater Des 37:410–415

    Article  Google Scholar 

  26. Zhang Z, Shan J-G, Tan X-H, Zhang J (2016) Effect of anodizing pretreatment on laser joining CFRP to aluminum alloy A6061. Int J Adhes Adhes 70:142–151

    Article  Google Scholar 

  27. Rodríguez-Vidal E, Sanz C, Soriano C, Leunda J, Verhaeghe G (2016) Effect of metal micro-structuring on the mechanical behavior of polymer–metal laser T-joints. J Mater Process Technol 229:668–677

    Article  Google Scholar 

  28. Z. Zhang, J. Shan, X. Tan, J. Zhang, Improvement of the laser joining of CFRP and aluminum via laser pre-treatment, The International Journal of Advanced Manufacturing Technology, (2016)

    Google Scholar 

  29. Zinn C, Bobbert M, Dammann C, Wang Z, Tröster T, Mahnken R, Meschut G, Schaper M (2018) Shear strength and failure behaviour of laser nano-structured and conventionally pre-treated interfaces in intrinsically manufactured CFRP-steel hybrids. Compos Part B 151:173–185

    Article  Google Scholar 

  30. Genna S, Lambiase F, Leone C (2018) Effect of laser cleaning in laser assisted joining of CFRP and PC sheets. Compos Part B 145:206–214

    Article  Google Scholar 

  31. Lambiase F, Genna S, Leone C, Paoletti A (2017) Laser-assisted direct-joining of carbon fibre reinforced plastic with thermosetting matrix to polycarbonate sheets. Opt Laser Technol 94:45–58

    Article  Google Scholar 

  32. Lambiase F, Paoletti A, Grossi V, Di Ilio A (2019) Analysis of loads, temperatures and welds morphology in FSW of polycarbonate. J Mater Process Technol 266:639–650

    Article  Google Scholar 

  33. Lambiase F, Ko D-C (2017) Two-steps clinching of aluminum and carbon Fiber reinforced polymer sheets. Compos Struct 164:180–188

    Article  Google Scholar 

Download references

Acknowledgments

The authors would like to thank Mr. Giuseppe Organtini (DIIIE - University of L’Aquila) to contribute during the setup and conduction of the experimental tests and Dr. Lorenzo Arrizza for his support during SEM analysis.

Author information

Authors and Affiliations

  1. Department of Industrial and Information Engineering and Economics, University of L’Aquila, via G. Gronchi 18, Zona Industriale di Pile, 67100 (AQ), L’Aquila, Italy

    F. Lambiase, V. Grossi, A. Di Ilio & A. Paoletti

Authors
  1. F. Lambiase
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. V. Grossi
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. A. Di Ilio
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. A. Paoletti
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to F. Lambiase.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Lambiase, F., Grossi, V., Di Ilio, A. et al. Feasibility of friction stir joining of polycarbonate to CFRP with thermosetting matrix. Int J Adv Manuf Technol 106, 2451–2462 (2020). https://doi.org/10.1007/s00170-019-04814-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-019-04814-8

Keywords

Search

Navigation