Joining of Metal-Thermoplastic-Tube-Joints by Hydraulic Expansion

F. Weber, Peter Lehmenkühler, M. Hahn, A. Tekkaya
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Abstract

To encounter current issues regarding climate change, the hybridization of structures with lighter, often dissimilar, materials is an essential cornerstone of lightweight design. The different mechanical behavior of these materials results in challenges in terms of joining. This paper utilizes the joining process by hydraulic expansion to manufacture tube-to-tube joints of aluminum alloy AA6060 T66 and thermoplastic polycarbonate (Lexan) at room temperature. In contrast to metals, elastic and plastic strains coexist in thermoplastics from the beginning of deformation. Based on the theory of linear elasticity, an equation was derived to calculate the fluid pressure that expands the polycarbonate up to a strain value where plastic strains start to increase significantly in comparison to elastic strains. Tensile tests of the joined tubes revealed that the transferable tensile load increased approximately exponentially with increasing plastic deformation of the polycarbonate. With ongoing plastic deformation, micro-cracks appeared and merged within the thermoplastic. The appearance of these so-called crazes had no negative influence on the transferable load within the range of applied fluid pressure.
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金属-热塑性管-接头的水力膨胀连接
为了应对当前有关气候变化的问题,结构与更轻、通常不同的材料的杂交是轻量化设计的重要基石。这些材料的不同力学性能导致了连接方面的挑战。本文采用液压膨胀连接工艺,在室温下制造了铝合金AA6060 T66与热塑性聚碳酸酯(Lexan)的管对管连接。与金属相反,热塑性塑料从变形开始就存在弹性和塑性应变。基于线弹性理论,推导出了使聚碳酸酯膨胀至某一应变值的流体压力方程,此时塑性应变开始比弹性应变显著增加。连接管的拉伸试验表明,随着聚碳酸酯塑性变形的增加,可转移拉伸载荷近似呈指数增长。随着塑性变形的不断进行,热塑性材料内部出现微裂纹并融合。这些所谓的裂纹的出现对施加流体压力范围内的可转移载荷没有负面影响。
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