On the feasibility of a friction-based staking joining method for polymer–metal hybrid structures. (15th February 2016)

• Record Type: Journal Article
• Authors: Abibe, A.B.; Sônego, M.; dos Santos, J.F.; Canto, L.B.; Amancio-Filho, S.T.
• Is Part Of: Materials & design. Volume 92(2016)
• Page Start: 632
• Page End: 642
• Publication Date: 2016-02-15
• Subjects: Processing technologies -- Staking -- Polymer–metal structures -- Hybrid joining -- Friction joining -- Polyetherimide; Materials -- Periodicals; Engineering design -- Periodicals; Matériaux -- Périodiques; Conception technique -- Périodiques; Electronic journals; 620.11
• DOI: 10.1016/j.matdes.2015.12.087
• Languages: English
• ISSNs: 0264-1275

Abstract

Abstract: The increased use of hybrid structures to reduce weight currently faces the limitations of traditional joining methods. Consequently there is a niche for development of new joining techniques, which can reduce or overcome some of the existing limitations. This paper presents for the first time the new Friction-based Injection Clinching Joining technique (F-ICJ), describing the microstructure and changes in local properties of joints between polyetherimide (PEI) and aluminum alloy 6082-T6. A shear layer around the rotating tool composes a polymer thermomechanically affected zone (PTMAZ), which presents pores as a result of evolution of gaseous products. The PTMAZ shows decreases of 8% to 12% in local strength compared to the base material, as measured by microhardness. Ultimate forces of 1419 ± 43 N in lap shear and 430 ± 44 N in cross tensile were achieved for F-ICJ joints. These levels are similar to ultrasonic staking joints of the same material combination, but the hollow design of F-ICJ stakes accounts for improved strength-to-weight ratio (18% in lap shear, 21% in cross tensile). Although the F-ICJ process currently requires longer cycles (7.5 s) than state-of-the-art ultrasonic staking (2.8–2.9 s), generated results indicate that the F-ICJ process is a competitive staking joining method with potential for improvement. Graphical abstract: Highlights: A friction-based alternative (F-ICJ) to current staking joining methods is presented. The new method is feasible with transportation industry materials (PEI/AA6082-T6). Effects of processing on joint microstructure and local properties are described. F-ICJ process is compared to state-of-the-art ultrasonic staking.