A novel joining technology for metal and polymer sheets

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY Journal of Advanced Joining Processes Pub Date : 2024-01-04 DOI:10.1016/j.jajp.2024.100184
MM Kasaei , RJC Carbas , EAS Marques , LFM da Silva
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Abstract

This paper introduces a novel joining process for producing hybrid metal-polymer joints. The process, called hole hemming, involves deforming the metal sheet to establish a mechanical interlock with the polymer sheet, requiring neither heating nor auxiliary elements. The applicability of this process is tested for joining aluminum and polycarbonate (PC) sheets. Initially, an analytical design method is presented to achieve a connection without failure and with a mechanical interlock. Subsequently, the accuracy of the predictions is assessed through experiments and finite element simulations, employing the modified Mohr-Coulomb criterion for the prediction of ductile damage. Additionally, a new design for hole-hemmed joints, involving the incorporation of branches in the hole of the outer sheet, is introduced to expand the process window of this novel joining technology. Finally, the mechanical behavior of four different types of hybrid hole-hemmed joints (HHH joints) are evaluated through single-lap shear tests. The results show that the hole hemming process can successfully join AA6082-T4 and PC sheets, validating the proposed designs and ideas. The new hybrid joints demonstrate a maximum force and displacement of 1.6 kN and 12.9 mm, respectively, in the shear test, indicating significant potential of the proposed technology for joining metal and polymer sheets.

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金属和聚合物板材的新型连接技术
本文介绍了一种用于生产金属-聚合物混合接头的新型连接工艺。这种工艺被称为 "孔折边",它通过使金属板变形来与聚合物板建立机械互锁,既不需要加热,也不需要辅助元件。我们对铝板和聚碳酸酯(PC)板的连接工艺进行了测试。首先提出了一种分析设计方法,以实现无故障连接和机械互锁。随后,通过实验和有限元模拟,采用修正的莫尔-库仑准则来预测韧性破坏,评估了预测的准确性。此外,还介绍了一种新的孔铰接设计,即在外层板的孔中加入分支,以扩大这种新型连接技术的工艺窗口。最后,通过单圈剪切试验评估了四种不同类型的混合孔铰接接头(HHH 接头)的机械性能。结果表明,孔边工艺可以成功连接 AA6082-T4 和 PC 板,验证了所提出的设计和想法。在剪切试验中,新型混合接头的最大力和位移分别达到 1.6 kN 和 12.9 mm,这表明所提出的技术在连接金属和聚合物板材方面具有巨大潜力。
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来源期刊
CiteScore
7.10
自引率
9.80%
发文量
58
审稿时长
44 days
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