Abstract
Recently, the applications of carbon fiber reinforced polymer (CFRP) in marine, automobile, aerospace, and other industries have increased significantly. Due to great physical and chemical differences between CFRP and metal, it is not easy to join them together, and this is one of the key problems that many industries need to solve. Thus, a systematic review of the achievements in joining CFRP and metal by welding process is presented in this study to understand the joining mechanism of these materials. Different types of joining methods, such as supersonic welding, laser welding, friction welding, composite welding, and other techniques are studied. The research shows that all different welding methods have pros and cons, and the usage of hybrid joining will be the future trend to improve the joint performance with respect to the joining application of CFRP and metal. In the time ahead, these methods can provide some references for the development of technologies used in joining CFRP and metal.Keywords:
carbon fiber reinforced polymer, metal, welding, reviewReferences
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2. Gupta G., Kumar A., Tyagi R., Kumar S., Application and future of composite materials: A review, Journal of Innovative Research in Science, Engineering and Technology, 5(5): 6907–6911, 2016, https://doi.org/10.15680/IJIRSET.2016.0505041
3. Casavola C., Palano F., De Cillis F., Tati A., Terzi R., Luprano V., Analysis of CFRP joints by means of T-pull mechanical test and ultrasonic defects detection, Materials, 11(4): 620, 2018, https://doi.org/10.3390/ma11040620
4. Pagano F., Paulmier P., Kaminski M., Thionnet A., Numerical and experimental approach for improving quasi-static and fatigue testing of a unidirectional CFRP composite laminate, Procedia Engineering, 213: 804–815, 2018, https://doi.org/10.1016/j.proeng.2018.02.076
5. Jambor A., Beyer M., New cars – new materials, Materials and Design, 18(4–6): 203–209, 1997, https://doi.org/10.1016/S0261-3069%2897%2900049-6
6. Benedyk J., Light metals in automotive applications, Light Metal Age, 10(1): 34–35, 2000.
7. Toyota's Lexus LFA uses carbon composites, Reinforced Plastics, 54(1): 8, 2010.
8. Li Y., Lin Z., Jiang A., Chen G., Experimental study of glass-fiber mat thermoplastic material impact properties and lightweight automobile body analysis, Materials & Design, 25(7): 579–585, 2004, https://doi.org/10.1016/j.matdes.2004.02.018
9. Dawei Z., Qi Z., Xiaoguang F., Shengdun Z., Review on joining process of carbon fiber-reinforced polymer and metal: methods and joining process, Rare Metal Materials and Engineering, 47(12): 3686–3696, 2018, https://doi.org/10.1016/S1875-5372%2819%2930018-9
10. Kweon J.-H., Jung J.-W., Kim T.-H., Choi J.-H., Kim D.-H., Failure of carbon composite-to-aluminum joints with combined mechanical fastening and adhesive bonding, Composite Structures, 75(1–4): 192–198, 2006, https://doi.org/10.1016/j.compstruct.2006.04.013
11. Di Franco G., Fratini L., Pasta A., Ruisi A.F., On the self-piercing riveting of aluminium blanks and carbon fibre composite panels, International Journal of Material Forming, 6(1): 137–144, 2013.
12. Di Franco G., Fratini L., Pasta A., Analysis of the mechanical performance of hybrid (SPR/bonded) single-lap joints between CFRP panels and aluminum blanks, International Journal of Adhesion and Adhesives, 41: 24–32, 2013.
13. Huang Z., Sugiyama S., Yanagimoto J., Hybrid joining process for carbon fiber reinforced thermosetting plastic and metallic thin sheets by chemical bonding and plastic deformation, Journal of Materials Processing Technology, 213(11): 1864–1874, 2013, https://doi.org/10.1016/j.jmatprotec.2013.04.015
14. Schonhorn H., Hansen R.H., Surface treatment of polymers for adhesive bonding, Journal of Applied Polymer Science, 11(8): 1461–1474, 1967, https://doi.org/10.1002/app.1967.070110809
15. Davies P., Cantwell W.J., Jar P.Y., Bourban P.E., Zysman V., Kausch H.H., Joining and repair of a carbon fibre-reinforced thermoplastic, Composites, 22(6): 425–431, 1991, https://doi.org/10.1016/0010-4361%2891%2990199-Q
16. Pramanik A., Basak A.K., Dong Y., Sarker P.K., Uddin M.S., Littlefair G., Dixit A.R., Chattopadhyaya S., Joining of carbon fibre reinforced polymer (CFRP) composites and aluminium alloys – A review, Composites Part A: Applied Science and Manufacturing, 101: 1–29, 2017, https://doi.org/10.1016/j.compositesa.2017.06.007
17. Heng L., Joining Technology [in Chinese], Higher Education Press, Beijing, 2010.
18. Balle F., Wagner G., Eifler D., Ultrasonic spot welding of aluminum sheet/carbon fiber reinforced polymer – joints, Materialwissenschaft und Werkstofftechnik, 38(11): 934–938, 2007, https://doi.org/10.1002/mawe.200700212
19. Balle F., Wagner G., Eifler D., Ultrasonic metal welding of aluminium sheets to carbon fibre reinforced thermoplastic composites, Advanced Engineering Materials, 11(1–2): 35–39, 2009, https://doi.org/10.1002/adem.200800271
20. Wagner G., Balle F., Eifler D., Ultrasonic welding of aluminum alloys to fiber reinforced polymers, Advanced Engineering Materials, 15(9): 792–803, 2013, https://doi.org/10.1002/adem.201300043
21. Tan X., Shan J., Ren J., Effects of Cr plating layer on shear strength and interface bonding characteristics of mild steel/CFRP joint by laser heating, Acta Metallurgica Sinica, 49(6): 751–756, 2013, https://doi.org/10.3724/SP.J.1037.2013.00045
22. Jung K.W., Kawahito Y., Takahashi M., Katayama S., Laser direct joining of carbon fiber reinforced plastic to zinc-coated steel, Materials & Design, 47: 179–188, 2013, https://doi.org/10.1016/j.matdes.2012.12.015
23. Liu S., Zhou J., Li Y., Zhang X., Using reaction heat of laser-induced Al-Ti-C interlayer to connect CFRTP/aluminum, Optics & Laser Technology, 113: 365–373, 2019, https://doi.org/10.1016/j.optlastec.2018.12.044
24. Zhang Z., Shan J., Tan X., Zhang J., Improvement of the laser joining of CFRP and aluminum via laser pre-treatment, The International Journal of Advanced Manufacturing Technology, 90(9–12): 3465–3472, 2017, https://doi.org/10.1007/s00170-016-9646-5
25. Xie Y., Friction Stir Welding of Homogenous FRTP and Dissimilar [in Chinese], FRTP/Aluminum Alloy Nanchang, Nanchang Hangkong University, 2012.
26. Huang Y., Meng X., Xie Y., Li J., Wan L., Joining of carbon fiber reinforced thermoplastic and metal via friction stir welding with co-controlling shape and performance, Composites Part A: Applied Science and Manufacturing, 112: 328–336, 2018, https://doi.org/10.1016/j.compositesa.2018.06.027
27. Tanaka K., Teramura T., Katayama T., Nishiguchi K., Friction stir spot welding of CFRP and aluminum alloy with themoplastic adhesive, WIT Transactions on The Built Environment, High Performance and Optimum Design of Structures and Materials II, 166: 391–401, 2016, https://doi.org/10.2495/HPSM160371
28. Karami Pabandi H., Movahedi M., Kokabi A.H., A new refill friction spot welding process for aluminum/polymer composite hybrid structures, Composite Structures, 174: 59–69, 2017.
29. Nagatsuka K., Yoshida S., Tsuchiya A., Nakata K., Direct joining of carbon-fiber–reinforced plastic to an aluminum alloy using friction lap joining, Composites Part B: Engineering, 73: 82–88, 2015, https://doi.org/10.1016/j.compositesb.2014.12.029
30. Buffa G., Baffari D., Campanella D., Fratini L., An Innovative Friction Stir Welding Based Technique to Produce Dissimilar Light Alloys to Thermoplastic Matrix Composite Joints, Procedia Manufacturing, 5: 319–331, 2016, https://doi.org/10.1016/j.promfg.2016.08.028
31. Goushegir S.M., dos Santos J.F., Amancio-Filho S.T., Friction Spot Joining of aluminum AA2024/carbon-fiber reinforced poly(phenylene sulfide) composite single lap joints: Microstructure and mechanical performance, Materials & Design, 54: 196–206, 2014, https://doi.org/10.1016/j.matdes.2013.08.034
32. Esteves J.V., Goushegir S.M., dos Santos J.F., Canto L.B., Hage Jr. E., Amancio-Filho S.T., Friction spot joining of aluminum AA6181-T4 and carbon fiber-reinforced poly(phenylene sulfide): Effects of process parameters on the microstructure and mechanical strength, Materials & Design, 66(Part B): 437–445, 2015, https://doi.org/10.1016/j.matdes.2014.06.070
33. André N.M., Goushegir S.M., dos Santos J.F., Canto L.B., Amancio-Filho S.T., Friction spot joining of aluminum alloy 2024-T3 and carbon-fiber-reinforced poly(phenylene sulfide) laminate with additional PPS film interlayer: Microstructure, mechanical strength and failure mechanisms, Composites Part B: Engineering, 94: 197–208, 2016, https://doi.org/10.1016/j.compositesb.2016.03.011
34. Amancio-Filho S.T., Bueno C., dos Santos J.F., Huber N., Hage Jr.. E., On the feasibility of friction spot joining in magnesium/fiber-reinforced polymer composite hybrid structures, Materials Science and Engineering: A, 528(10–11): 3841–3848, 2011, https://doi.org/10.1016/j.msea.2011.01.085
35. Hu Z., Haiyang Y., Lin H., A connection method between carbon fiber composite and metal[in Chinese], Hu Bei, CN108406147A, 2018-08-17.
36. Hong L., Xusheng L., Zhuoxin L., Yi H., Ultrasonic assisted aluminum alloy/composite material backfilling friction stir adhesive spot welding joint process [in Chinese], Beijing, CN109465535A, 2019-03-15.
37. Ageorges C., Ye L., Resistance welding of metal/thermoplastic composite joints, Journal of Thermoplastic Composite Materials, 14(6): 449–475, 2001.
38. Acherjee B., Hybrid laser arc welding: State-of-art review, Optics & Laser Technology, 99: 60–71, 2018, https://doi.org/10.1016/j.optlastec.2017.09.038
39. Katayama S., Kawahito Y., Mizutani M., Latest progress in performance and understanding of laser welding, Physics Procedia, 39: 8–16, 2012, https://doi.org/10.1016/j.phpro.2012.10.008
40. Thomas W.M. et al., Friction Stir Butt Welding, International Patent Application No PCT/GB92, No. 9125978.8, 6 December 1991.
41. Yoon S.-O., Kang M.-S., Nam H.-B., Kwon Y.-J., Hong S.-T., Kim J.-C., Lee K.-H., Lim C.-Y., Seo J.-D., Friction stir butt welding of A5052-O aluminum alloy plates, Transactions of Nonferrous Metals Society of China, 22(Supplement 3): s619–s623, 2012.
42. Mishra R.S., Ma Z.Y., Friction stir welding and processing, Materials Science and Engineering: R: Reports, 50(1–2): 1–78, 2005, https://doi.org/10.1016/j.mser.2005.07.001
43. Mubiayi M.P., Akinlabi E.T., Makhatha M.E., Current Trends in Friction Stir Welding (FSW) and Friction Stir Spot Welding (FSSW), Springer International Publishing, 2019, https://doi.org/10.1007/978-3-319-92750-3
44. Zhiqian T., Tiehao Z., Study on friction stir welding technology of 6005A-T6 aluminum alloy for high-speed train [in Chinese], Journal of Mechanical Engineering, 44(11): 63–68, 2017.
45. Delany F., Kallee S.W., Russell M.J., Friction stir welding of aluminium ships, Electric Welding Machine, 37(6): 48–57, 2007.
46. Lohwasser D., Application of friction stir welding for air-craft industry, The 2nd International Symposium on Friction Stir Welding, Gothenburg, Sweden, June 26–28, 2000.
47. Gao J., Li C., Shilpakar U., Shen Y., Improvements of mechanical properties in dissimilar joints of HDPE and ABS via carbon nanotubes during friction stir welding process, Materials & Design, 86: 289–296, 2015, https://doi.org/10.1016/j.matdes.2015.07.095
48. Wahid M.A., Khan Z.A., Siddiquee A.N., Review on underwater friction stir welding: A variant of friction stir welding with great potential of improving joint properties, Transactions of Nonferrous Metals Society of China, 28(2): 193–219, 2018, https://doi.org/10.1016/S1003-6326%2818%2964653-9
49. Huang Y., Meng X., Xie Y., Li J., Si X., Fan Q., Improving mechanical properties of composite/metal friction stir lap welding joints via a taper-screwed pin with triple facets, Journal of Materials Processing Technology, 268: 80–86, 2019, https://doi.org/10.1016/j.jmatprotec.2019.01.011
50. Bilici M.K., Yukler A.I., Effects of welding parameters on friction stir spot welding of high density polyethylene sheets, Materials & Design, 33: 545–550, 2012, https://doi.org/10.1016/j.matdes.2011.04.062
51. Yusof F., bin Muhamad M.R., Moshwan R., bin Jamaludin M.F., Miyashita Y., Effect of surface states on joining mechanisms and mechanical properties of aluminum alloy (A5052) and polyethylene terephthalate (PET) by dissimilar friction spot welding, Metals, 6(5): 101, 2016, https://doi.org/10.3390/met6050101
52. Lambiase F., Paoletti A., Di Ilio A., Friction spot stir welding of polymers: control of plunging force, The International Journal of Advanced Manufacturing Technology, 90(9–12): 2827–2837, 2017, https://doi.org/10.1007/s00170-016-9586-0
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