Abstract
In this study, we present improved fusion-bonding strength results between carbon fiber-reinforced polyetheretherketone (CFR-PEEK) and zinc-coated steel through the introduction of pre-inscribed laser surface patterns. Optimized laser welding parameters, including laser power, focal position, pitch, number of passes, and clamping pressure, are presented along with parameters for producing the rectangular laser patterns. It was found that for the optimized parameters, the tensile shear strength of the welded samples is improved by as much as 100% when pre-inscribed laser patterns are present. Detailed SEM images of the fractured fusion welded joint samples after the tensile shear test are presented for analysis. The tight bonding between the polymer matrix and the zinc-coated steel inside the formed grooves is found to be the main reason behind the increased tensile shear strength. A comparison of the tensile shear loads for various joining methods is also presented and discussed.
Highlights
Carbon fiber-reinforced plastic (CFRP) is an attractive material candidate for weight reduction due to its high strength-to-weight ratio compared to metals
We investigate the influence of pre-inscribed laser surface patterning, via nanosecond pulse laser, on the laser fusion-bonding strength of carbon fiber-reinforced polyetheretherketone (CFR-PEEK) and zinc-coated steel
The optimal laser power was chosen since the results show high tensile shear load test results for all the focal lengths with a minimum amount of errors
Summary
Carbon fiber-reinforced plastic (CFRP) is an attractive material candidate for weight reduction due to its high strength-to-weight ratio compared to metals. It is especially promising for the automotive industry since toughening environmental regulations and high fuel prices have demanded reduced carbon emissions and improved fuel efficiency [1,2,3]. The lack of reliable and productive means for joining dissimilar materials has limited the use of CFRPs. Only a handful of methods for joining CFRP and other metals have been used such as chemical binders and a few mechanical means. Thermoplastic CFRPs, on the other hand, allow fusion welding and can be a good alternative for increasing the production efficiency [4,5,6,7].
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