Advertisement

Ultrasonic Welding of Polymer–Metal Hybrid Joints

  • Anwer Al-ObaidiEmail author
  • Candice MajewskiEmail author
Conference paper
Part of the Transactions on Intelligent Welding Manufacturing book series (TRINWM)

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).

Keywords

Ultrasonic welding Amorphous polymer Aluminium alloy Hybrid joints 

References

  1. 1.
    Zain-Ul-Abdein M (2009) Experimental investigation and numerical simulation of laser beam welding induced residual stresses and distortions in aa 6056-t4 sheets for aeronautic application. Bibliography 41(2):48–60Google Scholar
  2. 2.
    AWS (2013) Welding handbook, 53Google Scholar
  3. 3.
    Raza SF (2015) Ultrasonic welding of thermoplastics. SheffieldGoogle Scholar
  4. 4.
    Benatar A, Eswaran RV, Nayar SK (1989) Ultrasonic welding of thermoplastics in the near-field. Polym Eng Sci 29(23):1689–1698CrossRefGoogle Scholar
  5. 5.
    Michael J (2009) Handbook of plastics joiningGoogle Scholar
  6. 6.
    Troughton MJ (2008) Handbook of plastics joining—a practical guide. William Andrew PublishingGoogle Scholar
  7. 7.
    Ensminger D, Bond LJ (2011) Ultrasonics: fundamentals, technology and applications. CRC PressGoogle Scholar
  8. 8.
    Graff K (2005) Ultrasonic metal welding. In: New developments in advanced welding, pp 241–269CrossRefGoogle Scholar
  9. 9.
    Neppiras EA (1965) Ultrasonic welding of metals. Ultrasonics 3(3):128–135CrossRefGoogle Scholar
  10. 10.
    Ginzburg SK, Nosov YG (1967) Characteristics of diffusion processes in commercial iron during ultrasonic welding. Met Sci Heat Treat 9(4):306–308CrossRefGoogle Scholar
  11. 11.
    Lewis WJ, Antonevich JN, Monroe RE et al (1960) Fundamental studies on the mechanism of ultrasonic weldingGoogle Scholar
  12. 12.
    Sooriyamoorthy E, John Henry SP, Kalakkath P (2010) Experimental studies on optimization of process parameters and finite element analysis of temperature and stress distribution on joining of Al–Al and Al–Al2O3 using ultrasonic welding. Int J Adv Manuf Technol 55(5–8):631–640Google Scholar
  13. 13.
    AlSarraf, SZ (2013) A study of ultrasonic metal welding. University of GlasgowGoogle Scholar
  14. 14.
    Wagner G, Balle F, Eifler D (2013) Ultrasonic welding of aluminum alloys to fiber reinforced polymers. Adv Eng Mater 15(9):792–803CrossRefGoogle Scholar
  15. 15.
    Wright NW (2012) Implementation of ultrasonic welding in the automotive industry. University of ManchesterGoogle Scholar
  16. 16.
    Bakavos D, Prangnell PB (2010) Mechanisms of joint and microstructure formation in high power ultrasonic spot welding 6111 aluminium automotive sheet. Mater Sci Eng, A 527(23):6320–6334CrossRefGoogle Scholar
  17. 17.
    Patel VK, Bhole SD, Chen DL (2011) Influence of ultrasonic spot welding on microstructure in a magnesium alloy. Scr Mater 65(10):911–914CrossRefGoogle Scholar
  18. 18.
    Lee S (2013) Process and quality characterization for ultrasonic welding of lithium-ion batteries. Cell Physiol Biochem 32(32):645–654Google Scholar
  19. 19.
    Mason RL, Gunst RF, Hess JL (2003) Statistical design and analysis of experiments: with applications to engineering and scienceGoogle Scholar
  20. 20.
    Mathews PG (2005) Design of experiments with MINITAB. ASQ Quality PressGoogle Scholar
  21. 21.
    Roy RK (2001) Design of experiments using the Taguchi approach: 16 steps to product and process improvement. WileyGoogle Scholar
  22. 22.
    Bradley N (2007) The response surface methodology. Indiana University South Bend, p73Google Scholar
  23. 23.
    Asghar A, Abdul Raman AA, Daud WMAW (2014) A comparison of central composite design and Taguchi method for optimizing Fenton process. Sci World J 2014:869120CrossRefGoogle Scholar
  24. 24.
    Elangovan S, Prakasan K, Jaiganesh V (2010) Optimization of ultrasonic welding parameters for copper to copper joints using design of experiments. Int J Adv Manuf Technol 51(1–4):163–171CrossRefGoogle Scholar
  25. 25.
    Eswaran R (1988) Near field ultrasonic welding of thermoplastics. The Ohio State UniversityGoogle Scholar
  26. 26.
    Liu SJ, Lin WF, Chang BC et al (1999) Optimizing the joint strength of ultrasonically welded thermoplastics. Adv Polym Technol 18(2):125–135CrossRefGoogle Scholar
  27. 27.
    Nonhof CJ, Luiten GA (1996) Estimates for process conditions during the ultrasonic welding of thermoplastics. Polym Eng Sci 36(9):1177–1183CrossRefGoogle Scholar

Copyright information

© Springer Nature Singapore Pte Ltd. 2019

Authors and Affiliations

  1. 1.Mechanical Engineering DepartmentUniversity of SheffieldSheffieldUK
  2. 2.Mechanical Engineering DepartmentUniversity of WasitWasitIraq

Personalised recommendations