Abstract
The ultrasonic joining process was recently introduced as an alternative concept to join through-the-thickness reinforced metal-composite hybrid structures. In this work, the investigation of joining process parameters effect on the joint mechanical performance of Ti-6Al-4V-glass-fiber-reinforced polyetherimide overlap joints was carried out by Box-Behnken design of experiments. The individual and combined effects of joining energy, sonotrode oscillation amplitude, and joining pressure on the ultimate lap shear force were elucidated by response surfaces method and analysis of variance. As a result of this study, a set of optimized joining parameters were obtained to produce joints with high ultimate lap shear force. The obtained reliable reduced model (R2 = 82%) displays a major influence of joining energy (25.3%) and sonotrode oscillation amplitude (21.2%) on the joint mechanical performance. Two-way interaction response surfaces were used to support strategies to optimize the maximum ultimate lap shear force. By comparing the optimized joint condition produced in this work with previously published results an improvement of 79% in ultimate lap shear force was attained, thereby, proving the potential of the proposed process optimization procedure.
Highlights
The application of multi-material structures has been increasing over the last years, especially in the transportation sector
Recent developments on the joining of metal-composite hybrid structures [4, 5] suggest that through-the-thickness reinforcement (TTR) integrated on the metal part surface can increase the mechanical performance of metal-composite overlap joints
In order to understand the effect of process parameters on the ULSF and optimize the process to produce stronger joints, a
Summary
The application of multi-material structures has been increasing over the last years, especially in the transportation sector. Adequate lightweight materials selection supports the transportation sector to Recommended for publication by Commission III - Resistance Welding, Solid State Welding, and Allied Joining Process. Recent developments on the joining of metal-composite hybrid structures [4, 5] suggest that through-the-thickness reinforcement (TTR) integrated on the metal part surface can increase the mechanical performance of metal-composite overlap joints. Such concepts are classified in a new class of joining technologies called direct assembling (DA). In order to decrease the assembling cycles, while still producing joints improved out-of-plane performance, the ultrasonic joining (U-Joining)
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