Study on the SPCC and CFRTP Hybrid Joint Performance Produced with Additional Nylon-6 Interlayer by Ultrasonic...

Area of Science:

• Materials Science
• Manufacturing Engineering

Background:

• Joining dissimilar materials like metal and carbon fiber presents significant challenges due to property differences.
• Traditional joining methods are often inadequate for hybrid structures.

Purpose of the Study:

• To investigate ultrasonic plastic welding of cold rolled steel (SPCC) and carbon fiber reinforced thermoplastic (CFRTP) using a Nylon 6 (PA6) thermoplastic film interlayer.
• To determine the effects of ultrasonic welding energy and preheating temperature on joint microstructure and mechanical properties.

Main Methods:

• Ultrasonic plastic welding was employed to create SPCC-CFRTP hybrid joints with a PA6 interlayer.
• Microstructural analysis and lap shear tests under quasi-static loading were conducted.
• The influence of varying welding energy and preheating temperatures (up to 200°C and 240°C) was systematically evaluated.

Main Results:

• The addition of a PA6 film interlayer facilitated strong hybrid joints between SPCC and CFRTP.
• Preheating temperature significantly impacted the SPCC-PA6 interface; eliminating crevices at 200°C increased joint strength.
• Optimal joining parameters, particularly a preheating temperature of 240°C, maximized joint strength, with welding energy and preheating temperature acting synergistically.

Conclusions:

• The PA6 interlayer is critical for successful ultrasonic welding of SPCC and CFRTP.
• Controlling the interface between the metal and the polymer interlayer is key to achieving high joint strength.
• An optimized process window for ultrasonic welding of these hybrid materials was established, enabling robust joint fabrication.