Feasibility study on hybrid weld-bonding between dissimilar material for automotive industry

• Type: Article in International Scientific Journal
• Date: 2023

Authors

Nonnenmann, T (Author) Other; Beygi, R (Author) Other; Ricardo Carbas (Author) FEUP; da Silva, LFM (Author) FEUP; Ochsner, A (Author) Other

Journal

Title: International Journal of Adhesion and Adhesives

Vol. 121

ISSN: 0143-7496

Publisher: Elsevier

Indexing

ISI Web of Knowledge - 0 Citations

Scopus - 0 Citations

Other information

Authenticus ID: P-00X-PTP

DOI: 10.1016/j.ijadhadh.2022.103316

Abstract (EN): Nowadays, the replacement of steel with lightweight materials such as aluminum causes an increased demand for joining of dissimilar materials in the automotive and aerospace industries. Dissimilar joining of components with Adhesive Bonding (AB) is a widely used method that distributes the load over a greater area than mechanical joints. However, peak stresses at the overlap edges results in premature failure. A solution to alleviate this problem is to implement a hybrid weld-bonded joint to reduce the stress concentration at the edges. In this study, the focus was to manufacture a hybrid weld-bonded joint where Friction-Stir-Spot-Welding (FSSW) was applied at the overlap edges. Tensile shear tests were performed to achieve the fracture load of various joint designs. The fracture surfaces were investigated, and numerical simulation was performed to achieve the fracture load of various joint designs. The fracture surfaces were investigated, and numerical simulation was performed to analyse the fracture mechanism and the interaction between adhesive bond and FSSW. In one of the test series, FSSW was applied in the overlap area near the edges of a similar lap-joint (Al-Al). Here, the adhesive bonding was burnt by the friction of the spinning tool and delaminated. Moreover, the material flow during FSSW was influenced by the presence of the adhesive bonding. To mitigate the interference between AB/FSSW, the spot weld was applied at the overlap edges. The results show that by bringing the FSSW closer to the edge, the bilateral detrimental interaction of AB and FSSW can be significantly reduced. However, the failure load of the hybrid bonded joint was still lower than the adhesive bonded one. Based on the results of the present study, FSSW and AB should be located as far as possible (at least for the selected adhesive) due to their completely different mechanisms of joining. The results can be informative for the development of new hybrid joining configurations with high performance.

Language: English

Type (Professor's evaluation): Scientific

No. of pages: 11