The application of advanced materials, i.e. advanced ceramics, glasses, intermetallic phases and various type of composites, not only depends on their manufacture processes including a great input of know-how, but als...The application of advanced materials, i.e. advanced ceramics, glasses, intermetallic phases and various type of composites, not only depends on their manufacture processes including a great input of know-how, but also on their abilities for processing, among which the joining processes play an important role. The uses of advanced materials are changing rapidly, with a major emphasis on technical applications, especially the components of machines, apparatus and technical devices expected to withstand very heavy exploitation conditions. Furthermore,these materials are becoming more complex, in terms of being strengthened and toughened by transformation processes as well as by the addition of other ceramic or metallic materials including nanomaterials. The successful use of advanced materials requires the development of equally advanced joining materials, processes and technology. Some selected examples of results of joining advanced materials with the use of various procedures as well as surface modification of structural components with the use of advanced materials obtained in the Welding Engineering Department of Warsaw University of Technology, Poland, are presented.展开更多
Composite interlayer materials containing active elements was designed, with the aid of EDAX, XRD analysis technology and thermal elastic plastic finite element analysis in 3 demensions. When a suitable composite inte...Composite interlayer materials containing active elements was designed, with the aid of EDAX, XRD analysis technology and thermal elastic plastic finite element analysis in 3 demensions. When a suitable composite interlayer material was adopted in the diffusion bonding of HPSN to K 500, the bending strength of the joints would be up to 216 MPa and 218 MPa at room temperature and 800℃ respectively.展开更多
Vaporizing foil actuator welding(VFAW) was used for joining 2024-T3 and 7075-T6 aluminum alloy sheets, and the resulting joint microstructure was analyzed. 2024/7075 aluminum alloy pairs with suitable processing param...Vaporizing foil actuator welding(VFAW) was used for joining 2024-T3 and 7075-T6 aluminum alloy sheets, and the resulting joint microstructure was analyzed. 2024/7075 aluminum alloy pairs with suitable processing parameters can be prepared by using VFAW. Dynamic preform addresses the poor formability problem of target material and advantage of VFAW on dissimilar materials in some conditions. But with standoff sheet inserting in the flyer and target, 2024/7075 welded pairs gets the better weld strength, compared with flyer preformed method. The microstructure of the circular weld area of the welded joint showed a wave interface, in which a thin melt layer formed at the center and edge parts. The crystal grains near the bonding interface were remarkably elongated and refined. Therefore, the joining of the 2024/7075 pairs was facilitated through plastic forming and melting.展开更多
Organic sheets made out of fiber-reinforced thermoplastics are able to make a crucial contribution to increase the lightweight potential of a design. They show high specific strength- and stiffness properties, good da...Organic sheets made out of fiber-reinforced thermoplastics are able to make a crucial contribution to increase the lightweight potential of a design. They show high specific strength- and stiffness properties, good damping characteristics and recycling capabilities, while being able to show a higher energy absorption capacity than comparable metal constructions. Nowadays, multi-material designs are an established way in the automotive industry to combine the benefits of metal and fiber-reinforced plastics. Currently used technologies for the joining of organic sheets and metals in large-scale production are mechanical joining technologies and adhesive technologies. Both techniques require large overlapping areas that are not required in the design of the part. Additionally, mechanical joining is usually combined with “fiber-destroying” pre-drilling and punching processes. This will disturb the force flux at the joining location by causing unwanted fiber- and inter-fiber failure and inducing critical notch stresses. Therefore, the multi-material design with fiber-reinforced thermoplastics and metals needs optimized joining techniques that don’t interrupt the force flux, so that higher loads can be induced and the full benefit of the FRP material can be used. This article focuses on the characterization of a new joining technology, based on the Cold Metal Transfer (CMT) welding process that allows joining of organic sheets and metals in a load path optimized way, with short cycle times. This is achieved by redirecting the fibers around the joining area by the insertion of a thin metal pin. The path of the fibers will be similar to paths of fibers inside structures found in nature, e.g. a knothole inside of a tree. As a result of the bionic fiber design of the joint, high joining strengths can be achieved. The increase of the joint strength compared to blind riveting was performed and proven with stainless steel and orthotropic reinforced composites in shear-tests based on the DIN EN ISO 14273. Every specimen joined with the new CMT Pin joining technology showed a higher strength than specimens joined with one blind rivet. Specimens joined with two or three pin rows show a higher strength than specimens joined with two blind rivets.展开更多
We determined the effects of the penetration depth and spline material and composite material type as well as joining method on bending moment resistance under diagonal compression and tension in common wood panel str...We determined the effects of the penetration depth and spline material and composite material type as well as joining method on bending moment resistance under diagonal compression and tension in common wood panel structures. Composite materials were laminated medium density fiberboard （MDF） and particleboard. Joining methods were butt and miter types. Spline materials were high density fiberboard （HDF）. The penetration depths of plywood, wood （Carpinus betolus） and spline were 8, 11 and 14 mm. The results showed that in both diagonal com- pression and tension, MDF joints are stronger than particleboard joints, and the bending moment resistance under compression is higher compared with that in tension. The highest bending moment resistance under tension was shown in MDF, butt joined using plywood spline with 8 mm penetration depth, whereas under compression bending moment resistance was seen in MDF, miter joined with the HDF spline of 14 mm penetration depth.展开更多
Reliable line production processes and simulation tools play a central role for the structural integration of thermoplastic composites in advanced lightweight constructions. Provided that material-adapted joining tech...Reliable line production processes and simulation tools play a central role for the structural integration of thermoplastic composites in advanced lightweight constructions. Provided that material-adapted joining technologies are available, they can be applied in heavy-duty multi-material designs (MMD). A load-adapted approach was implemented into the new fully automatic and fault-tolerant thermo mechanical flow drill joining (FDJ) concept. With this method it is possible to manufacture reproducible high strength FRP/metal-joints within short cycle times and without use of extra joining elements for the first time. The analysis of FDJ joints requires a simplified model of the joint to enable efficient numerical simulations. The present work introduces a strategy in modeling a finite-element based analogous-approach for FDJ-joints with glass fiber reinforced polypropylene and high-strength steel. Combined with a newly developed section-force related failure criterion, it is possible to predict the fundamental failure behavior in multi-axial stress states. The functionality of the holistic approach is illustrated by a demonstrator that represents a part of a car body-in-white structure. The comparison of simulated and experimentally determined failure loads proves the applicability for several combined load cases.展开更多
文摘The application of advanced materials, i.e. advanced ceramics, glasses, intermetallic phases and various type of composites, not only depends on their manufacture processes including a great input of know-how, but also on their abilities for processing, among which the joining processes play an important role. The uses of advanced materials are changing rapidly, with a major emphasis on technical applications, especially the components of machines, apparatus and technical devices expected to withstand very heavy exploitation conditions. Furthermore,these materials are becoming more complex, in terms of being strengthened and toughened by transformation processes as well as by the addition of other ceramic or metallic materials including nanomaterials. The successful use of advanced materials requires the development of equally advanced joining materials, processes and technology. Some selected examples of results of joining advanced materials with the use of various procedures as well as surface modification of structural components with the use of advanced materials obtained in the Welding Engineering Department of Warsaw University of Technology, Poland, are presented.
文摘Composite interlayer materials containing active elements was designed, with the aid of EDAX, XRD analysis technology and thermal elastic plastic finite element analysis in 3 demensions. When a suitable composite interlayer material was adopted in the diffusion bonding of HPSN to K 500, the bending strength of the joints would be up to 216 MPa and 218 MPa at room temperature and 800℃ respectively.
基金Funded by the State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body(No.31815008)the National Natural Science Foundation of China(No.U1564202,NO.51205298)111 Project(No.B17034)
文摘Vaporizing foil actuator welding(VFAW) was used for joining 2024-T3 and 7075-T6 aluminum alloy sheets, and the resulting joint microstructure was analyzed. 2024/7075 aluminum alloy pairs with suitable processing parameters can be prepared by using VFAW. Dynamic preform addresses the poor formability problem of target material and advantage of VFAW on dissimilar materials in some conditions. But with standoff sheet inserting in the flyer and target, 2024/7075 welded pairs gets the better weld strength, compared with flyer preformed method. The microstructure of the circular weld area of the welded joint showed a wave interface, in which a thin melt layer formed at the center and edge parts. The crystal grains near the bonding interface were remarkably elongated and refined. Therefore, the joining of the 2024/7075 pairs was facilitated through plastic forming and melting.
基金financially supported by the High-Tech Research and Development Program of China(No.SS2013AA031305)the Key Technologies R&D Program of Tianjin(No.12ZCDGGX49100)
文摘Organic sheets made out of fiber-reinforced thermoplastics are able to make a crucial contribution to increase the lightweight potential of a design. They show high specific strength- and stiffness properties, good damping characteristics and recycling capabilities, while being able to show a higher energy absorption capacity than comparable metal constructions. Nowadays, multi-material designs are an established way in the automotive industry to combine the benefits of metal and fiber-reinforced plastics. Currently used technologies for the joining of organic sheets and metals in large-scale production are mechanical joining technologies and adhesive technologies. Both techniques require large overlapping areas that are not required in the design of the part. Additionally, mechanical joining is usually combined with “fiber-destroying” pre-drilling and punching processes. This will disturb the force flux at the joining location by causing unwanted fiber- and inter-fiber failure and inducing critical notch stresses. Therefore, the multi-material design with fiber-reinforced thermoplastics and metals needs optimized joining techniques that don’t interrupt the force flux, so that higher loads can be induced and the full benefit of the FRP material can be used. This article focuses on the characterization of a new joining technology, based on the Cold Metal Transfer (CMT) welding process that allows joining of organic sheets and metals in a load path optimized way, with short cycle times. This is achieved by redirecting the fibers around the joining area by the insertion of a thin metal pin. The path of the fibers will be similar to paths of fibers inside structures found in nature, e.g. a knothole inside of a tree. As a result of the bionic fiber design of the joint, high joining strengths can be achieved. The increase of the joint strength compared to blind riveting was performed and proven with stainless steel and orthotropic reinforced composites in shear-tests based on the DIN EN ISO 14273. Every specimen joined with the new CMT Pin joining technology showed a higher strength than specimens joined with one blind rivet. Specimens joined with two or three pin rows show a higher strength than specimens joined with two blind rivets.
文摘We determined the effects of the penetration depth and spline material and composite material type as well as joining method on bending moment resistance under diagonal compression and tension in common wood panel structures. Composite materials were laminated medium density fiberboard （MDF） and particleboard. Joining methods were butt and miter types. Spline materials were high density fiberboard （HDF）. The penetration depths of plywood, wood （Carpinus betolus） and spline were 8, 11 and 14 mm. The results showed that in both diagonal com- pression and tension, MDF joints are stronger than particleboard joints, and the bending moment resistance under compression is higher compared with that in tension. The highest bending moment resistance under tension was shown in MDF, butt joined using plywood spline with 8 mm penetration depth, whereas under compression bending moment resistance was seen in MDF, miter joined with the HDF spline of 14 mm penetration depth.
文摘Reliable line production processes and simulation tools play a central role for the structural integration of thermoplastic composites in advanced lightweight constructions. Provided that material-adapted joining technologies are available, they can be applied in heavy-duty multi-material designs (MMD). A load-adapted approach was implemented into the new fully automatic and fault-tolerant thermo mechanical flow drill joining (FDJ) concept. With this method it is possible to manufacture reproducible high strength FRP/metal-joints within short cycle times and without use of extra joining elements for the first time. The analysis of FDJ joints requires a simplified model of the joint to enable efficient numerical simulations. The present work introduces a strategy in modeling a finite-element based analogous-approach for FDJ-joints with glass fiber reinforced polypropylene and high-strength steel. Combined with a newly developed section-force related failure criterion, it is possible to predict the fundamental failure behavior in multi-axial stress states. The functionality of the holistic approach is illustrated by a demonstrator that represents a part of a car body-in-white structure. The comparison of simulated and experimentally determined failure loads proves the applicability for several combined load cases.
