Não é possível apresentar esta imagem de momento. Page 0 Não é possível apresentar esta imagem de momento. FP7 Research Project MetalMorphosis Optimization of joining processes for new automotive metal-composite hybrid parts Joining of tubular metal-composite parts using the electromagnetic pulse technology Workshop Koen Faes Irene Kwee Belgian Welding Institute
35
Embed
FP7 Research Project MetalMorphosis · FP7 Research Project MetalMorphosis Optimization of joining processes for new automotive metal-composite hybrid parts . Joining of tubular metal
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Não é possível apresentar esta imagem de momento.
Page 0
Não é possível apresentar esta imagem de momento.
FP7 Research Project MetalMorphosis Optimization of joining processes for new automotive metal-composite hybrid parts
Joining of tubular metal-composite parts using the electromagnetic pulse technology Workshop
Koen Faes
Irene Kwee
Belgian Welding Institute
Page 1
Não é possível apresentar esta imagem de momento.
MetalMorphosis - Motivation Motivation:
– increased use of composites in the automotive industry for weight reduction, – development of a cost-effective joining method for metals and composites
Use of the electromagnetic pulse technology: Extension of the application range towards joining of metals and composites
Page 2
Não é possível apresentar esta imagem de momento.
Electromagnetic pulse techn.: Process principles
Coil
Field shaper
Workpiece
Page 3
Não é possível apresentar esta imagem de momento.
Process principles : Variants
Welding Crimping
interference and form fit joints
Page 4
Não é possível apresentar esta imagem de momento.
Variant : Electromagnetic pulse welding
Copper - Steel
Copper - Stainless steel
Aluminium - Aluminium
Copper - Brass
Page 5
Não é possível apresentar esta imagem de momento.
Variant : Electromagnetic pulse crimping
Page 6
Não é possível apresentar esta imagem de momento.
Joining concepts for tubular products
Interference fit joints: – Concept 1 : Connection of a metal tube with a solid composite part – Concept 2 : Connection of a metal tube with a tubular composite part
Form fit joints: – Concept 3 : Connection of a metal tube with a profiled solid composite part : single groove – Concept 4 : Connection of a metal tube with a profiled solid composite part : double groove – Concept 5 : Connection of a metal tube with a solid or tubular composite part – Concept 6 : Connection of a solid or tubular metal part with a tubular composite part, using an
external ring – Concept 7 : Connection of a metal tube with a solid composite part, with a single groove & insert – Concept 8 : Connection of a metal-composite hybrid part with another metal part – Concept 9 : Connection of a metal tube with a solid composite part, with a double groove & insert
Page 7
Não é possível apresentar esta imagem de momento.
Joining concepts for tubular products Interference fit joints: the outer tubular part is deformed plastically and the internal part
deforms elastically
Concept 1 : Connection of a metal tube with a solid composite part
Concept 2 : Connection of a metal tube with a tubular composite part Composite tube supported by an insert placed inside the tube
Page 8
Não é possível apresentar esta imagem de momento.
Joining concepts Form fit joints: undercuts (e.g. grooves) are used in the internal part and the other tube is
deformed into these undercuts, creating a mechanical interlock
Concept 3 : Connection of a metal tube with a profiled solid composite part : single groove
Concept 4 : Connection of a metal tube with a profiled solid composite part : double grooves
Page 9
Não é possível apresentar esta imagem de momento.
Joining concepts Concept 5 : Connection of a metal tube with a solid or tubular composite part
Metal tube foreseen with a grooved internal surface, e.g. an internal screw thread or an internal knurled surface
Composite tube internally supported by an insert
Concept 6 : Connection of a solid or tubular metal part with a tubular composite part, using an external ring Similar as concept 5, but in addition the metal bar is foreseen with a profiled outer surface
Page 10
Não é possível apresentar esta imagem de momento.
Joining concepts Concept 7 : Connection of a metal tube with a solid composite part, with a single groove
and metal insert
Concept 9 : Connection of a metal tube with a solid composite part, with a double groove and metal insert
Page 11
Não é possível apresentar esta imagem de momento.
Joining concepts Concept 8 : Connection of a metal-composite hybrid part with another metal part
Possibilities for the manufacturing of hybrid parts
Page 12
Não é possível apresentar esta imagem de momento.
Materials Metal tube material :
– Aluminium: EN AW-6082 T6 (40 x 2 mm) – Steel: E235+C (38,7 x 1,42 mm)
Parameter variation: – Groove edge radius: 1 & 2 mm – Discharge energy
Joint of GC22 & aluminium
Page 25
Não é possível apresentar esta imagem de momento.
Composite fracture behaviour
Concept 4 – GE & aluminium
No cracks nor degradation of composite
Cracks in the composite core or degradation at the groove edge or at the outer surface of the composite
Observations :
Increase of discharge energy ⇒ increase of degradation
Lack of correlation between the groove geometry and fracture behaviour
Joint of GE & alu
Page 26
Não é possível apresentar esta imagem de momento.
Tensile test: 4 fracture modes for joints of GE glass reinforced epoxy & aluminium
Concept 4 – GE & aluminium
< 43 kN
- Aluminium tube slides off, without fracture - No composite fracture - For majority of the joints
- Aluminium tube slides off, without fracture - Composite fracture
> 43 kN
- Aluminium tube fractures in the longitudinal direction - No composite fracture - For majority of the joints
- Aluminium tube fractures in the circumferential direction
- No composite fracture
Page 27
Não é possível apresentar esta imagem de momento.
Comparison: range of tensile forces and corresponding discharge energies
Concept 4 – Double groove, without insert
Page 28
Não é possível apresentar esta imagem de momento.
Concept 3 (single) vs. Concept 4 (double groove) Comparison: range of tensile forces and corresponding discharge energies
Page 29
Não é possível apresentar esta imagem de momento.
Concept 7 – Single groove, with insert In general:
– Comparable joint strengths (21 – 44 kN) – Impact resistance of PA6.6 is higher (up
to 13 kJ) compared to GC203 (up to 11 kJ)
– Different fracture modes
Higher tensile strength for: – A smaller groove edge radius
(0,75 mm - 1 mm) – A larger groove & insert edge angle
(θ = 90°) At a higher energy for GC203, but at lower energy for PA6.6
A higher impact resistance for: – A large groove depth (2,5 mm) ⇒ prevents aluminium tube from
impacting on the groove bottom – A larger insert edge angle (90°) ⇒ avoids tensile forces induced by the
inwards movement of tube
Joint of PA6.6GF30 & alu Joint of EP GC203 & alu
Page 30
Não é possível apresentar esta imagem de momento.
Concept 9 – Double groove, with insert Connection of a metal tube with a profiled solid composite part: double groove, with insert
Composite material : PA6.6GF30 bars
Aluminium 6082 tubes
Parameter variation: – Discharge energy – Groove edge radius: 1 & 2 mm
Impact resistance: – Allowable energy levels up to 14 kJ – No effect of the groove radius on the impact resistance
Tensile force: – Range 51 – 53 kN – Lack of correlation between groove edge radii and tensile force
Page 31
Não é possível apresentar esta imagem de momento.
Comparison: range of tensile force and corresponding discharge energies
Concept 4 (double groove & without insert) & vs. Concept 9 (double groove & with insert)
Page 32
Não é possível apresentar esta imagem de momento.
Comparison: range of tensile forces and corresponding discharge energies
Concepts 3 vs. 4 vs. 7 vs. 9 for joints of PA6.6GF30 & aluminium
Page 33
Não é possível apresentar esta imagem de momento.
Joining concepts: – Form fit joints provide a higher tensile force than interference fit joints – Joining concepts with a double groove (concept 4) or with an insert wit a double groove (concept 9) provides the
highest tensile force and impact resistance, due to: Mechanical interlock of the tube into the grooves or inserts of the composite Larger distance for the tube to cover prior impact onto the composite Metal insert protects the composite against the impacting tube
Composites: – EP GC22 with double groove & without insert: high impact resistance (11 kJ) & highest tensile force (57-65 kN) – PA6.6GF30 with double groove & with insert: highest impact resistance (14 kJ) & high tensile force (51-53 kN)
Metal tubes: – Steel:
Higher tensile force and higher impact resistance, But: higher energy for crimping and composite fracture during tensile testing
– Aluminium: Lower tensile force and lower impact resistance, But: lower energy for crimping and aluminium fracture during tensile testing
Conclusions
Page 34
Não é possível apresentar esta imagem de momento.
This project is performed within the 7th Framwork Progamme funded European Research and Technological Development
Contact: Belgian Welding Institute Dr. ir. Koen Faes [email protected] +32(0)9/292.14.00