Download or read book Joining of Metal and Fiber Reinforced Polymers Using Ultrasonic Additive Manufacturing written by Hongqi Guo (Product design engineer) and published by . This book was released on 2021 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Various methods have been reported to join carbon fiber reinforced polymer (CFRP) composites with aluminum alloy (AA), with strengths ranging from 13 MPa to 112 MPa. This research project presents a new method for joining carbon fiber reinforced composites and metals using ultrasonic additive manufacturing (UAM), a solid-state manufacturing technology. Dry fibers are embedded in a metal matrix to create mechanical interlocking between the fiber and metal. After the UAM process, the dry fiber-metal joint can be interleaved with additional fiber fabrics to create FRP components with metal tabs that enable the FRP to be joined with metal structures using conventional metal-metal joining techniques. A manufacturing approach for producing continuous CFRP and aluminum alloy (AA) joints is developed. Mechanical testing demonstrates that the joints achieve a 129.5 MPa tensile strength. The failure mode can be designed to be fiber failure or metal failure based on the fiber-to-metal bearing area ratio. Failure in metal leads to high peak load, and failure in fiber is associated with high energy absorption due to fiber pull-out after initial fracture. The utilization of resistance spot welding (RSW) to join the UAM CFRP-AA joints to bulk AA is investigated by mechanical testing and hardness mapping. In addition to the coupon-level mechanical tests, structure-level tests are performed to evaluate the benefits of UAM CFRP-AA joints. CFRP-AA hybrid beam structures are manufactured using RSW through CFRP-AA joints with the settings developed previously. Benchmarked against pop rivets, experimental results show that the beam structures with UAM joints introduce benefits in energy absorption and force efficiency in four-point bend, axial crush, and torsion. An analytical model is developed based on the thick-wall cylindrical pressure vessel theory. The model is able to predict the tensile peak load and failure mode of the joints based on the material properties and joint design. An FEA model is created based on parameters calculated from the analytical model. The FEA model accurately predicts the tensile behavior of the CFRP-AA joints. A countermeasure to galvanic corrosion is developed by applying a Kevlar fiber reinforced polymer (KFRP) buffer to insulate the CFRP-AA couple. A 12-year equivalent corrosion cyclic test (CCT) is performed. The result demonstrates that the CFRP-KFRP-AA joint can maintain 95\% tensile strength and achieve zero mass loss. The technique of UAM FRP-metal joining has been applied to 1010 steel. A UAM manufacturing process is developed to create 1010 bonding with high shear strength at room temperature. Tensile tests are performed on KFRP-1010 steel joints and KFRP tow failure mode is achieved with high strength. RSW and corrosion studies are also carried out on the steel-based joints.
Download or read book Joining Carbon Fiber and Aluminum with Ultrasonic Additive Manufacturing written by Mark Bryant Gingerich and published by . This book was released on 2016 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: Due to increasing emphasis on lightweighting to increase fuel efficiency, integration of carbon fiber reinforced polymers (CFRP) with metal structures is necessary. Current adhesive and mechanical fastening methods used for joining CFRP to metals are not ideal due to poor mechanical properties and incompatibility with current manufacturing infrastructure. Consequently, new joining techniques are needed for increasing the use of CFRP. In this research project, a method of creating joints between CFRP and 6061-H18 aluminum was developed by using ultrasonic additive manufacturing (UAM). The UAM process was used to embed dry carbon fiber tows within an aluminum matrix, creating a mechanical joint between the two materials. The joints were then integrated with additional CF fabrics and epoxy, forming a fully integrated CF-Al structure. This technique was used to create CF-Al joints for tensile, cross tensile, and three-point-bend testing. Mechanical test results showed that the UAM constructed joints had superior strength when compared to adhesive single lap joints. Throughout the UAM joint manufacturing process, experimental observations paired with FEA were used to help solve issues with foil tearing, which is a common problem experienced when materials are embedded with UAM.
Download or read book Additive Manufacturing written by Emrah Celik and published by Walter de Gruyter GmbH & Co KG. This book was released on 2020-07-06 with total page 151 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book covers additive manufacturing of polymers, metals, ceramics, fiber reinforced polymer composites, energy harvesting materials, and biomaterials. Hybrid manufacturing is discussed. Topology optimization methodology is described and finite element software examples are provided. The book is ideal for graduate students and career starters in the industry.
Download or read book Joining of Polymer Metal Hybrid Structures written by Sergio T. Amancio Filho and published by John Wiley & Sons. This book was released on 2017-12-21 with total page 429 pages. Available in PDF, EPUB and Kindle. Book excerpt: A comprehensive introduction to the concepts of joining technologies for hybrid structures This book introduces the concepts of joining technology for polymer-metal hybrid structures by addressing current and new joining methods. This is achieved by using a balanced approach focusing on the scientific features (structural, physical, chemical, and metallurgical/polymer science phenomena) and engineering properties (mechanical performance, design, applications, etc.) of the currently available and new joining processes. It covers such topics as mechanical fastening, adhesive bonding, advanced joining methods, and statistical analysis in joining technology. Joining of Polymer-Metal Hybrid Structures: Principles and Applications is structured by joining principles, in adhesion-based, mechanical fastened, and direct-assembly methods. The book discusses such recent technologies as friction riveting, friction spot joining and ultrasonic joining. This is used for applications where the original base material characteristics must remain unchanged. Additional sections cover the main principles of statistical analysis in joining technology (illustrated with examples from the field of polymer-metal joining). Joining methods discussed include mechanical fastening (bolting, screwing, riveting, hinges, and fits of polymers and composites), adhesive bonding, and other advanced joining methods (friction staking, laser welding, induction welding, etc.). Provides a combined engineering and scientific approach used to describe principles, properties, and applications of polymer-metal hybrid joints Describes the current developments in design of experiments and statistical analysis in joining technology with emphasis on joining of polymer-metal hybrid structures Covers recent innovations in joining technology of polymer-metal hybrid joints including friction riveting, friction spot joining, friction staking, and ultrasonic joining Principles illustrated by pictures, 3D-schemes, charts, and drawings using examples from the field of polymer-metal joining Joining of Polymer-Metal Hybrid Structures: Principles and Applications will appeal to chemical, polymer, materials, metallurgical, composites, mechanical, process, product, and welding engineers, scientists and students, technicians, and joining process professionals.
Download or read book Hybrid Metal Additive Manufacturing written by Parnika Shrivastava and published by CRC Press. This book was released on 2023-12-05 with total page 269 pages. Available in PDF, EPUB and Kindle. Book excerpt: The text presents the latest research and development, technical challenges, and future directions in the field of hybrid metal additive manufacturing. It further discusses the modeling of hybrid additive manufacturing processes for metals, hybrid additive manufacturing of composite materials, and low-carbon hybrid additive manufacturing processes. THIS BOOK •Presents cutting-edge advancements and limitations in hybrid additive manufacturing technologies. • Discusses fabrication methods and rapid tooling techniques focusing on metals, composites, and alloys. •Highlights the importance of low-carbon additive manufacturing technologies toward achieving sustainability. •Emphasizes the challenges and solutions for integrating additive manufacturing and Industry 4.0 to enable rapid manufacturing of customized and tailored products. • Covers hybrid additive manufacturing of composite materials and additive manufacturing for fabricating high-hardness components. The text discusses the recent advancements in additive manufacturing of high-hardness components and covers important engineering materials such as metals, alloys, and composites. It further highlights defects and post-processing of hybrid additive manufacturing components, sustainability solutions for hybrid additive manufacturing processes, and recycling of machining waste into metal powder feedstock. It will serve as an ideal reference text for senior undergraduate and graduate students, and researchers in fields including mechanical engineering, aerospace engineering, manufacturing engineering, and production engineering.
Download or read book Ultrasonic Joining of Through the thickness Reinforced Metal composite Hybrid Structures written by Eduardo Etzberger Feistauer and published by . This book was released on 2018 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: Joining concepts that are traditionally used to join hybrid metal-composite structures present several limitations with regard to load transfer between the materials. The present doctoral thesis aims at introducing the Ultrasonic Joining (U-Joining), a new joining approach to produce through-the-thickness reinforced metal-composite hybrid joints that have improved out-of-plane strength. In order to demonstrate the process feasibility and describe the correlation between process and joint properties, a case study approach was chosen, using commercially available glass-fiber reinforced polyetherimide and MIM-Structured Ti-6Al-4V.
Download or read book Joining Processes for Dissimilar and Advanced Materials written by Pawan Kumar Rakesh and published by Woodhead Publishing. This book was released on 2021-11-13 with total page 692 pages. Available in PDF, EPUB and Kindle. Book excerpt: Joining Processes for Dissimilar and Advanced Materials describes how to overcome the many challenges involved in the joining of similar and dissimilar materials resulting from factors including different thermal coefficients and melting points. Traditional joining processes are ineffective with many newly developed materials. The ever-increasing industrial demands for production efficiency and high-performance materials are also pushing this technology forward. The resulting emergence of advanced micro- and nanoscale material joining technologies, have provided many solutions to these challenges. Drawing on the latest research, this book describes primary and secondary processes for the joining of advanced materials such as metals and alloys, intermetallics, ceramics, glasses, polymers, superalloys, electronic materials and composites in similar and dissimilar combinations. It also covers details of joint design, quality assurance, economics and service life of the product. Provides valuable information on innovative joining technologies including induction heating of metals, ultrasonic heating, and laser heating at micro- and nanoscale levels Describes the newly developed modelling, simulation and digitalization of the joining process Includes a methodology for characterization of joints
Download or read book Additive Manufacturing of Polymer Based Composite Materials written by Fabienne Touchard and published by Elsevier. This book was released on 2024-06-28 with total page 366 pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive Manufacturing of Polymer Composites: Materials, Processes, and Properties presents the latest developments in AM of polymer matrix composites and illustrates the large range of composite materials that can be obtained. Different technologies with their own specificities such as: fused filament fabrication, selective laser sintering, stereolithography, and direct-ink-writing. Composites with chopped or continuous reinforcement, with synthetic or natural fibers, with thermoplastic or thermoset resin are compared and described in detail. Their thermal, physical, electrical, and mechanical properties are discussed. The book is dedicated to professionals involved in engineering design and production, as well as industrial communities who want to gain in-depth knowledge in the field of 3D printed composites. Provides an overview of different methods for additive manufacturing of polymer-based matrix composites Covers long and short fiber-based composites and corresponding application examples Addresses the development and properties of a wide range of matrices (thermoplastics, thermosets), and fibers (natural and synthetic) in a user-specified orientation, continuous or random organization and hierarchical structures Presents sustainability and structural reliability of composite structures Displays a careful balance between materials science and technology, providing a detailed understanding of how composites’ properties, processing, performance, and structure are interrelated
Download or read book Metal Polymer Multi Material Structures and Manufacturing Techniques in Transportation written by Sergio T. Amancio-Filho and published by MDPI. This book was released on 2020-12-10 with total page 184 pages. Available in PDF, EPUB and Kindle. Book excerpt: The reduction of greenhouse gas emissions—particularly from fossil fuel-powered vehicles and airplanes by means of weight savings and leaner fuel consumption, helps to restrain environmental impacts. In general, for a variety of industries, and specifically in the case of transport, where both weight savings and increased energy efficiency are pursued, the use of metal–polymer multi-material structures has been growing at an increasing and particularly fast pace in recent years. Several manufacturing techniques have been, or are being, developed, with the aim of being used for producing dissimilar materials in cost-efficient manners. This book presents recent developments in the state of the art of advanced additive manufacturing and the joining of metal–polymer multi-material structures in transportation. This publication mainly focuses on the correlations between microstructure, manufacturing process (i.e., AddJoining, adhesive bonding, friction riveting, friction-based staking and friction spot joining) properties, and the mechanical performance of metal–polymer multi-material structures.
Download or read book Advanced Joining Processes written by Lucas F. M. da Silva and published by Springer Nature. This book was released on 2020-03-31 with total page 178 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book presents recent material science-based and mechanical analysis-based advances in joining processes. It includes all related processes, e.g. friction stir welding, joining by plastic deformation, laser welding, clinch joining, and adhesive bonding, as well as hybrid joints. It gathers selected full-length papers from the 1st Conference on Advanced Joining Processes.
Download or read book Joining of Materials and Structures written by Robert W. Messler and published by Elsevier. This book was released on 2004-08-24 with total page 815 pages. Available in PDF, EPUB and Kindle. Book excerpt: Joining of Materials and Structures is the first and only complete and highly readable treatment of the options for joining conventional materials and the structures they comprise in conventional and unconventional ways, and for joining emerging materials and structures in novel ways. Joining by mechanical fasteners, integral designed-or formed-in features, adhesives, welding, brazing, soldering, thermal spraying, and hybrid processes are addressed as processes and technologies, as are issues associated with the joining of metals, ceramics (including cement and concrete) glass, plastics, and composites (including wood), as well as, for the first time anywhere, living tissue. While focused on materials issues, issues related to joint design, production processing, quality assurance, process economics, and joint performance in service are not ignored. The book is written for engineers, from an in-training student to a seasoned practitioner by an engineer who chose to teach after years of practice. By reading and referring to this book, the solutions to joining problems will be within one’s grasp.Key Features:· Unprecedented coverage of all joining options (from lashings to lasers) in 10 chapters· Uniquely complete coverage of all materials, including living tissues, in 6 chapters· Richly illustrated with 76 photographs and 233 illustrations or plots· Practice Questions and Problems for use as a text of for reviewing to aid for comprehension * Coverage all of major joining technologies, including welding, soldering, brazing, adhesive and cement bonding, pressure fusion, riveting, bolting, snap-fits, and more* Organized by both joining techniques and materials types, including metals, non-metals, ceramics and glasses, composites, biomaterials, and living tissue* An ideal reference for design engineers, students, package and product designers, manufacturers, machinists, materials scientists
Download or read book Additive Manufacturing of Complex Shaped Metal ceramic Composites and Multilayered Metallic Structures written by Asaf Levy and published by . This book was released on 2017 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: "This work describes experimental results on components fabrication by an additive fabrication (AM) approach and is divided into two separate parts. Each of the fields described may stand by itself nevertheless together they emphasize the immanent potential of well-known materials systems with innovative advanced technology. he first part demonstrates innovative approach for the fabrication of functionally graded metal/ceramic composites (cermets) based on the Ti-C-Fe system. The second part is related to a new AM approach called Ultrasonic Additive Manufacturing (UAM) in which 3D structures are created by adding thin metal layers (>50μm) one on top of the other and joining them by applying ultrasonic vibrations combined with compressive normal force." -- From the abstract.
Download or read book Advances in Additive Manufacturing and Joining written by M. S. Shunmugam and published by Springer Nature. This book was released on 2019-10-16 with total page 749 pages. Available in PDF, EPUB and Kindle. Book excerpt: This volume presents research papers on additive manufacturing (popularly known as 3D printing) and joining which were presented during the 7th International and 28th All India Manufacturing Technology, Design and Research conference 2018 (AIMTDR 2018). The contents of this volume present the latest technological advancements for improving the efficiency, accuracy and speed of the additive manufacturing process and in fusion and solid-state welding technologies, with a variety of technologies, including fused deposition modelling, poly jet 3D printing, weld deposition based technology, selective laser melting and important welding technologies being covered. This volume will be of interest to academicians, researchers, and practicing engineers alike.
Download or read book Process Control and Development for Ultrasonic Additive Manufacturing with Embedded Fibers written by Adam J. Hehr and published by . This book was released on 2016 with total page 213 pages. Available in PDF, EPUB and Kindle. Book excerpt: Ultrasonic additive manufacturing (UAM) is a recent additive manufacturing technology which combines ultrasonic metal welding, CNC machining, and mechanized foil layering to create large gapless near net-shape metallic parts. The process has been attracting much attention lately due to its low formation temperature, the capability to join dissimilar metals, and the ability to create complex design features not possible with traditional subtractive processes alone. These process attributes enable light-weighting of structures and components in an unprecedented way. However, UAM is currently limited to niche areas due to the lack of quality tracking and inadequate scientic understanding of the process. As a result, this thesis work is focused on improving both component quality tracking and process understanding through the use of average electrical power input to the welder. Additionally, the understanding and application space of embedding fibers into metals using UAM is investigated, with particular focus on NiTi shape memory alloy fibers.
Download or read book Additive Manufacturing for Polymers written by Jianlei Wang and published by Frontiers Media SA. This book was released on 2023-10-16 with total page 94 pages. Available in PDF, EPUB and Kindle. Book excerpt: 3D printing, also known as additive manufacturing, is a manufacturing process that connects materials layer by layer to produce a solid object based on networked digital model files. Advantages of 3D printing over traditional manufacturing include less material consumption, lower costs, faster production process, customizable degrees of freedom and complexity of geometric shapes. The traditional manufacturing of a functional structural part often requires multiple independent process steps, while 3D printing can fabricate the same part in one step, enabling small batch production and customization of personalized products. Due to the diversity of materials available, 3D printing for polymer can be used to create lightweight complex structures in aerospace, models of architectural structures, art reproductions, and biological tissues and organs.
Download or read book Additive Manufacturing of High strength Continuous Fiber Reinforced Polymer Composites written by Pedram Parandoush and published by . This book was released on 2019 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive manufacturing (AM), also referred to as 3D printing, of polymer-fiber composites has transformed AM into a robust manufacturing paradigm and enabled producing highly customized parts with significantly improved mechanical properties compared to un-reinforced polymers. 3D printing of continuous carbon fiber reinforced thermoplastics (CFRTP) composites is increasingly under development owing to its unparalleled flexibility of manufacturing 3D structures over traditional manufacturing processes. However, key issues, such as weak interlayer bonding, voids between beads and layers, and low volume ratio of carbon fiber, in the mainstream fused deposition modeling (FDM) and extrusion suppress the applications of these techniques in mission-critical applications, such as aerospace and defense industries. In this work, we proposed a new laser assisted AM method that utilizes prepreg composites with continuous fiber reinforcement as feedstock to fabricate 3D objects by implementing laser assisted bonding and laser cutting. This technique is inspired by laminated object manufacturing (LOM), for AM of continuous CFRTPs using prepreg composite sheets. AM of continuous glass and carbon fiber reinforced thermoplastic composites is demonstrated using this technique. The continuous fiber reinforced prepreg is laser cut and laser bonded layer upon layer to produce 3D composite objects. Microstructure and mechanical properties (strength, modulus, interfacial, and shear properties) of the additively manufactured continuous fiber composites are studied and compared to other additive and conventional manufacturing methods. The interlayer properties of these additively manufactured composites was superior to other AM technologies, resulting to an excellent mechanical properties relative to other AM techniques. The microstructure analysis, by micro computed tomography (CT) scans, scanning electron microscopy (SEM), and optical microscopy, showed low void content and full consolidation of prepreg layers. The temperature at the material interface during the 3D process is crucial to achieve a strong bonding strength. This temperature can be predicted via the developed finite element (FE) heat transfer model in this work. This numerical model is able to predict the temperature history during the laser bonding process with great accuracy when compared to the experimental values. The surface quality of the additively manufactured CFRTPs were also studied and compared with the FDM technology. In addition, mechanical finishing methods, namely CNC milling and rotary ultrasonic machining (RUM), were employed to improve the surface quality of the 3D printed composites and drill precise holes in the structures. Overall, the proposed AM method can be broadly beneficial for industries requiring high performance and lightweight structural materials with complex geometries. This method is also easily scalable for high volume productions and could additionally reduce the waste associated with current CFRTP production techniques and improve the process from the production time standpoint by automation.
Download or read book Advanced Joining Processes written by Lucas F. M. da Silva and published by Elsevier. This book was released on 2020-10-31 with total page 402 pages. Available in PDF, EPUB and Kindle. Book excerpt: Advanced Joining Processes: Welding, Plastic Deformation, and Adhesion brings together a range of advanced thermal, mechanical, and chemical methods of joining, offering an up-to-date resource for those looking to understand and utilize the very latest techniques. Efficient joining techniques are critical to a range of innovative applications, with technology in constant development. The first section of the book provides in-depth information on advanced welding techniques, including friction stir, explosive, ultrasonic, laser, electron beam, and computational weld analysis and fatigue of structures. The second section highlights key developments in joining by plastic deformation, adhesive bonding, and hybrid joining. The coverage of each technique is supported by practical guidance, detailed analysis, and finite element simulations. This is an essential reference for researchers and advanced students in joining, welding, adhesion, materials processing, mechanical engineering, plastics engineering, manufacturing, civil engineering, and automotive/aerospace engineering, as well as engineers, scientists, and R&D professionals, using joining, welding, and adhesion methods, across a range of industries. Presents the latest research findings and developments across welding, joining by plastic deformation, and adhesion Includes state-of-the-art methods, such as laser, ultrasonic and electron beam welding, hybrid joining, and the use of electromagnetic pulses Offers practical guidance, detailed analysis, and finite element simulations, for all techniques covered
