Ultrasonic Welding of Polymer–Metal Hybrid Joints

Abstract

Joining of lightweight dissimilar materials becomes increasingly important, especially for structural applications and transportation industries to reduce the weight and thus decrease the fuel consumption and CO2 emissions. Previously, the joining of lightweight materials (metals and polymers) has been performed using mechanical fastenings, such as screws, bolts, and rivets, or adhesion techniques. However, the disadvantages of these mechanical methods are considerable stress concentration around the fastener hole, the potential in the corrosion problems, and potential in fatigue cracking in metallic materials. Ultrasonic welding is particularly suitable for applications with rapid process and high process reliability requirements. The quality, strength, and energy-saving technology also characterize ultrasonic welding. However, no research has been reported on joining lightweight dissimilar materials of thermoplastic polymers and metals using ultrasonic spot welding yet. Amorphous thermoplastic polymer (ABS-750SW) and aluminium alloy (Al6082-T6) are common engineering materials for manufacturing of hybrid structure and components for engineering applications. Our research shows that the ultrasonic welding of ABS and Al6082-T6 has been achieved successfully. The maximum lap shear strength obtained is 2.312 MPa (1.156 KN shear force).