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Metals
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Hybrid Metal-Polymer Joints
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Hybrid Metal-Polymer Joints

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Welding and Joining".

Deadline for manuscript submissions: closed (31 December 2022) | Viewed by 14355

Special Issue Editors

Dr. Francesco Lambiase

E-Mail Website
Guest Editor
Department of Industrial Engineering, University of L’Aquila, 67100 L’Aquila, Italy
Interests: hybrid joining; mechanical charcaterization; additive manufacturing; machine learning
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Sergio T. Amancio-Filho

E-Mail Website
Guest Editor
Institute of Materials Science, Joining and Forming, Graz University of Technology, 8010 Graz, Austria
Interests: joining technology; additive manufacturing; materials science; welding metallurgy; polymer welding; composites; metals and hybrid structures
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Multi-material hybrid structures (MMHSs) are highly demanded in several fields, including civil, transport, aerospace, and biomedical fields. In transportation industries, MMHSs are used to reduce a product's weight without affecting the structural performance, and consequently resulting in lower fuel consumption and, in the case of electric vehicles, to increase their autonomy. Furthermore, this weight reduction contributes dramatically to reducing CO2 emissions, as well as to improving the overall performance. The main challenge when manufacturing MMHSs is represented by the adoption of the joining process between such dissimilar materials. Conventional mechanical fastening and adhesive bonding involve several issues. Thus, because of the increasing demand for MMHSs, several new joining processes have been developed in order to overcome such limitations. Fast mechanical joining processes (such as clinching as self-pierce riveting) and thermomechanical joining processes (such as laser direct joining, friction joining, and ultrasonic joining) have been developed in recent years as suitable alternatives for the production of multi-materials hybrid structures.

This Special Issue is aimed at collecting original research and literature reviews concerning conventional processes and recent developments in this field. The following topics will be highly acknowledged:

  • Mechanism of bonding/joint formation;
  • Process monitoring and simulation;
  • Process control;
  • Influence of preprocessing;
  • Joining additively manufactured components;
  • Mechanical characterization;
  • Microstructural, chemical, and physical characterization;
  • Other characterization methods;
  • New characterization methods.

Prof. Dr. Francesco Lambiase
Prof. Dr. Sergio T. Amancio-Filho
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • hybrid structures
  • joining
  • welding
  • metal–polymer structures
  • metal–composite structures
  • characterization
  • process modeling
  • process control

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Published Papers (6 papers)

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Research

12 pages, 4651 KiB  
Article
Ultrasonic Joining of Additively Manufactured Metal-Composite Hybrid Joints: A Comparison between Vertical and Horizontal Vibration Modes
by Willian S. de Carvalho, Nathaniel F. Colvin, Avraham Benatar and Sergio T. Amancio-Filho
Metals 2023, 13(2), 319; https://doi.org/10.3390/met13020319 - 4 Feb 2023
Cited by 4 | Viewed by 2094
Abstract
Ultrasonic Joining (U-Joining) is a novel friction-based joining technique that produces through-the-thickness reinforced hybrid joints between surface-structured metals and thermoplastics. The process feasibility has been successfully demonstrated to join metals and unreinforced or fiber-reinforced polymer parts by applying horizontal vibration. However, intense tool [...] Read more.
Ultrasonic Joining (U-Joining) is a novel friction-based joining technique that produces through-the-thickness reinforced hybrid joints between surface-structured metals and thermoplastics. The process feasibility has been successfully demonstrated to join metals and unreinforced or fiber-reinforced polymer parts by applying horizontal vibration. However, intense tool wear was observed for the explored combinations of materials, which could diminish the mechanical performance of the produced joints and hinder the process application. These investigations left an unexplored field regarding the application of different vibration modes, which could represent good solutions to minimize the intense tool wear reported. Therefore, the present study aims to explore the application of vertical vibration and to identify possible advantages and disadvantages of this variation. The case-study combination of additively manufactured 316L stainless steel and 20%-short-carbon-fiber reinforced poly-ether-ether-ketone was selected for this purpose. Initially, a set of optimized joining parameters was obtained for the vertical variation following a one-factor-at-a-time approach. In a previous study, the joining parameters were already optimized for the horizontal mode, and the results were used for comparison purposes. Single-lap shear joints were produced using both optimized modes, and the process monitoring indicated that joints produced using vertical vibration reached a lower joining energy input for a given joining time. The produced joints were tested, and joints produced with the horizontal variation achieved higher ultimate lap shear forces than the ones achieved by the vertical ones: 3.6 ± 0.3 kN and 1.6 ± 0.3 kN, respectively. Microstructural investigations at the fractured surfaces showed that this difference is due to insufficient frictional heat generation at the metal-composite interface when vertical vibration is applied. Therefore, the temperatures reached during the joining cycle are not enough to melt the polymer completely at the interface, preventing a complete surface wetting of the metal and reducing the micromechanical interlocking and adhesion bond between the parts, thereby diminishing the mechanical performance of the produced joints. Full article
(This article belongs to the Special Issue Hybrid Metal-Polymer Joints)
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11 pages, 2320 KiB  
Article
The Influence of Coating and Adhesive Layers on the Mechanical Performance of Additively Manufactured Aluminum–Polymer Hybrid Joints
by Rielson Falck and Sergio T. Amancio-Filho
Metals 2023, 13(1), 34; https://doi.org/10.3390/met13010034 - 23 Dec 2022
Cited by 3 | Viewed by 1980
Abstract
AddJoining technique has been recently introduced to produce metal–polymer composite hybrid layered structures. The methodology combines the principles of joining and polymeric additive manufacturing. This paper presents three AddJoining process-variants investigated and demonstrated for the material combination aluminum 2024-T3 and acrylonitrile butadiene styrene [...] Read more.
AddJoining technique has been recently introduced to produce metal–polymer composite hybrid layered structures. The methodology combines the principles of joining and polymeric additive manufacturing. This paper presents three AddJoining process-variants investigated and demonstrated for the material combination aluminum 2024-T3 and acrylonitrile butadiene styrene to form hybrid single lap joints. The microstructure and mechanical performance were assessed. The process variant using heating control showed the ultimate lap shear force of 1.2 ± 0.05 kN and displacement at a break of 1.21 ± 0.16 mm as a result of strong bonding formation at the interface of the hybrid joints. For instance, the other two process variants tested (with epoxy adhesive, and with thin-acrylonitrile butadiene styrene (ABS) coating layer applied on the metal) presented reduced mechanical performance in comparison to process variant using heating control, namely approximately 42% and 8.3%, respectively. The former had a mixed adhesive–cohesive failure due to the lower bonding performance between the adhesive and ABS printed layers. The latter displayed a slight decrease in force in comparison to heat-control specimens. This could be explained by the presence of micro-voids formed by solvent evaporation at the ABS coating layer during AddJoining. Full article
(This article belongs to the Special Issue Hybrid Metal-Polymer Joints)
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19 pages, 6450 KiB  
Article
Microscale Damage Evolution and Failure Behavior of Metal–Composite Friction Spot Joints: Modelling and Experimental Analyses
by Natalia M. André, Renan Pereira Alessio, Jorge F. dos Santos and Sergio T. Amancio-Filho
Metals 2022, 12(12), 2080; https://doi.org/10.3390/met12122080 - 4 Dec 2022
Viewed by 1436
Abstract
This study aimed to understand the damage evolution at the interface of AA2024-T3/CF-PPS friction spot joints. For this purpose, the finite element method was applied and the bonding zones of the joints were discretized based on a traction–separation law. It was observed that [...] Read more.
This study aimed to understand the damage evolution at the interface of AA2024-T3/CF-PPS friction spot joints. For this purpose, the finite element method was applied and the bonding zones of the joints were discretized based on a traction–separation law. It was observed that the damage had initiated at the AZ (adhesion zone) and then propagated as a symmetric linear front from the edges towards the center of the joined area. Nevertheless, as the damage advanced inside the PDZ (plastically deformed zone), its propagation became an asymmetrical linear front that evolved preferably from the free edge of the composite part due to the higher peeling stresses in this region (asymmetrical secondary bending of the structure). Based on the findings of this study, modifications are proposed to the failure theory previously stated for friction spot joints. Full article
(This article belongs to the Special Issue Hybrid Metal-Polymer Joints)
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12 pages, 5689 KiB  
Article
Joining of Macroscopic 3D Steel Transition Wire Structures to Steel Sheets: Study on the Mechanical, Microstructural, and Phase Characteristics of Brazed and Glued Joints
by Saravanan Palaniyappan, Andreas Todt, Maik Trautmann, Felix Röder, Carolin Binotsch, Birgit Awiszus and Guntram Wagner
Metals 2022, 12(7), 1116; https://doi.org/10.3390/met12071116 - 29 Jun 2022
Viewed by 2000
Abstract
With an increased demand for the combination of different material classes in lightweight applications like automobiles, aircraft construction, etc., the need for simple and energy-efficient joining technologies to join these different material classes has been extensively researched over the last decades. One such [...] Read more.
With an increased demand for the combination of different material classes in lightweight applications like automobiles, aircraft construction, etc., the need for simple and energy-efficient joining technologies to join these different material classes has been extensively researched over the last decades. One such hybrid material combination is the metal–plastic hybrid structure, which offers the combinational characteristics of high strength and stiffness of the metal part along with characteristic elasticity and low density of the plastic part. In this research work, the focus is laid on generating a graded property transition at the interface of metal–plastic joints by brazing a three-dimensional (3D) macroscopic transition wire structure (TWS) strucwire®, over the metal part before being molded with plastic at a later stage using an injection over-molding process. This helps in providing a mechanical interlocking facility and thereby achieving a higher load transfer at the interface of metal–plastic hybrid joints. The graded steel wire structures with different carbon content were brazed onto the galvanized steel sheets using the hotplate brazing technique. In addition to the Zinc layer on the galvanized steel sheets, electroplated Zinc coatings were fabricated on the wire structures to provide better brazing quality. The microstructural, mechanical, and intermetallic phase characteristics of the resulting brazed joints were evaluated using light microscopy, adhesion tests, and scanning electron microscopy, respectively. Full article
(This article belongs to the Special Issue Hybrid Metal-Polymer Joints)
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21 pages, 5237 KiB  
Article
Mechanical Behavior of Multi-Material Single-Lap Joints under High Rates of Loading Using a Split Hopkinson Tension Bar
by Pascal Rüthnick, Noah Ledford, Mathieu Imbert and Michael May
Metals 2022, 12(7), 1082; https://doi.org/10.3390/met12071082 - 24 Jun 2022
Viewed by 1624
Abstract
In the presented research, a split Hopkinson tension bar (SHTB) was used to measure the mechanical response of multi-material single-lap joints in the high-rate loading regime. High-performance applications require high-quality measurements of the mechanical properties to define safe design rules. Servo-hydraulic machines are [...] Read more.
In the presented research, a split Hopkinson tension bar (SHTB) was used to measure the mechanical response of multi-material single-lap joints in the high-rate loading regime. High-performance applications require high-quality measurements of the mechanical properties to define safe design rules. Servo-hydraulic machines are commonly used to investigate such small structures, but they are prone to produce oscillation-affected force measurements. To improve force–displacement measurements, an SHTB was chosen to investigate these joints. Three different kinds of joints were tested: multi-material bolted joints, multi-material bonded joints, and multi-material bonded/bolted joints. One substrate of the joints was made of aluminum (Al-2024-T3) and the other one was made of a laminated composite (TC250). A countersunk titanium bolt and a crash-optimized epoxy adhesive (Betamate 1496 V) were used to fasten the joints. A constant impedance mounting device was implemented to limit wave reflections and to improve the signal quality. Quasi-static experiments at a servo-hydraulic machine were performed to compare the data with the respective data from the high-rate loading conditions. The presented research shows that high-quality high-rate tests of multi-material single-lap joints can be achieved by employing an SHTB. With this high-quality measurement, a rate dependency of the mechanical behavior of these joints was identified. The dynamic increase (DI), which is the ratio of a high rate of loading over quasi-static loading, was measured for each of the joint types, where the dynamic increase in the max force was DI = 1.1 for the bolted, DI = 1.4 for the bonded, and DI = 1.6 for the bonded/bolted joints. Full article
(This article belongs to the Special Issue Hybrid Metal-Polymer Joints)
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17 pages, 10894 KiB  
Article
A Study on the Bond Strength of Plastic–Metal Direct Bonds Using Friction Press Joining
by Stefan P. Meyer, Maren T. Herold, Jan B. Habedank and Michael F. Zaeh
Metals 2021, 11(4), 660; https://doi.org/10.3390/met11040660 - 18 Apr 2021
Cited by 6 | Viewed by 3627
Abstract
Friction press joining (FPJ) is an innovative joining process for bonding plastic components and metal sheets without additives in an overlap configuration. This paper focuses on the resulting bond strength. Tensile tests showed that the direct bonds produced by FPJ have either an [...] Read more.
Friction press joining (FPJ) is an innovative joining process for bonding plastic components and metal sheets without additives in an overlap configuration. This paper focuses on the resulting bond strength. Tensile tests showed that the direct bonds produced by FPJ have either an equivalent or a higher bond strength compared to adhesive bonds. For the material combination of HD-PE and EN AW-6082-T6, an equivalent bond strength was achieved. In contrast, for the material combinations PA6-GF30 with EN AW-6082-T6 and PPS-CF with EN AW-2024-T3, higher tensile shear strengths were achieved via the FPJ technology. In addition to the technical considerations, this paper presents an evaluation of the technological maturity of FPJ. It was found that the basics of the technology are already well developed, and prototypes for showing the applicability have already been manufactured. The last part of this paper deals with the classification of FPJ into the standard for manufacturing processes, according to DIN 8593. The authors suggest a categorization into Activation bonding (item 4.8.1.3). These investigations show the high technical potential of FPJ for joining plastic components with metals. Full article
(This article belongs to the Special Issue Hybrid Metal-Polymer Joints)
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