News from CD Welding MCS technology contributes to the economical and reliable production of fiber-reinforced plastic/metal hybrid structures. In addition to the use of pressure-hardened materials such as 22MnB5 with aluminium- silicon coating (AlSi coating), multi-material construction, especially with carbon fibre- reinforced plastics (CFRP), is increasingly being used to implement lightweight construction solutions. While 22MnB5 with AlSi coating is suitable for the joining technology processing of 22MnB5 which has already established capacitor discharge welding with MCS technology - comprehensive information can be found in a research report by KAPKON /2/ - the technology was now successfully used in a research project on the AiF project IGF No.: 19,466 N /1/ of RWTH Aachen University in March 2018 in the Joining Test Centre in Oyten. Within the scope of a project of RWTH Aachen University, metallic inserts were to be used as an integral component of a fiber composite component as a contact point for the welding process. The metallic Insert consists of a carrier plate and is provided with vertical pins, which are made of resin and glass fibres, in a further step surrounded by carbon fibers are. The pins of the insert are used by and joined by means of a resistance welding process. (see Figure 1). Capacitor charge welding is to be used as a joining technology to prevent thermal damage to the duoplastic fibre composite material. In the tests in the FtVZ, a combination pulse sequence generated by an MCS system could be used without any mechanical change-over of the transformer ratio Influence on the current rise time and thus on the way in can be taken. The sinking-in is not possible due to the layer-height of the composite material as a limiting factor a high level of attention was paid to contacting. Since the resin is absorbed by the effect of the electrode force is not deformed, the sinking path must be adapted to the pin height protruding from the layer. By using different capacitors and varied combination pulse sequences (see Figure 2) consisting of an initial pulse (I) for surface activation and a press pulse (II) for introducing the necessary joining energy, specific sinking paths could be set at an interval of 0.15 to 0.75 mm. Figure 3 shows a macrosection of the mixed connection after the joining process. The combination of two thermally coupled single pulses /3/ with current rise times of 0.51 ms also made it possible to significantly reduce the tendency to splatter and to reduce the time previously required within the scope of the project with inverter and CD single pulse technique by 90 %. The short welding time and the associated low heat input during the process is seen as a clear advantage for the future use of carbon fibers. Literature reference: /1/Lotte, J.: Entwicklung eines alternativen Fügever- fahrens zur wirtschaftlichen und prozesssicheren Her- stellung von faserverstärkten Kunststoff-/Metallhybrid- strukturen auf Basis des Widerstandsschweißverfahrens mittels integrierter metallischer Inserts. Aachen, RWTH Aachen, Institut für Schweißtechnik und Fügetechnik (ISF), 2017 (Forschungsvorhaben IGF-Nr.: 19,466 N) /2/Rusch, H.-J., Stocks, N.: KE-Mehr-Puls-Schweißen von Anschweißmuttern auf 22MnB5 + AS150. Oyten, KAPKON GmbH, Fügetechnisches Versuchszentrum, 2018 (Forschungsbericht) /3/Stocks, N.: Thermische Kopplung beim Mehr-Puls- Schweißen. In: Schweißzeit (2018), Nr. 1/18 Nicolas Stocks [email protected] Kapkon GmbH - Max-Planck-Str. 23 - D-32107 Bad Salzuflen Tel.: +49 (0) 52 22 98 36 50 - E-Mail: [email protected] - Internet: www.kapkon.de Combi-pulse sequence Figure 1 Snapshot of the inserted joining parts before the welding process Figure 3 Joined material combination of metallic insert and fibre-reinforced plastic Figure 2 temporal course of the current of a combination pulse sequence time in ms current in kA
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News from CD WeldingMCS technology contributes to the economical and reliable production of fiber-reinforced plastic/metal hybrid structures.
In addition to the use of pressure-hardened materials such as 22MnB5 with aluminium-silicon coating (AlSi coating), multi-material construction, especially with carbon fibre-reinforced plastics (CFRP), is increasingly being used to implement lightweight construction solutions. While 22MnB5 with AlSi coating is suitable for the joining technology processing of 22MnB5
which has already established capacitor discharge welding with MCS technology - comprehensive information can be found in a research report by KAPKON /2/ - the technology was now successfully used in a research project on the AiF project IGF No.: 19,466 N /1/ of RWTH Aachen University in March 2018 in the Joining Test Centre in Oyten.Within the scope of a project of RWTH Aachen University, metallic inserts were to be used as an integral component of a fiber composite component as a contact point for the welding process. The metallic Insert consists of a carrier plate and is provided with vertical pins, which are made of resin and glass fibres, in a further step surrounded by carbon fibers are. The pins of the insert are used by and joined by means of a resistance welding process. (see Figure 1).
Capacitor charge welding is to be used as a joining technology to prevent thermal damage to the duoplastic fibre composite material. In the tests in the FtVZ, a combination pulse sequence generated by an MCS system could be used without any mechanical change-over ofthe transformer ratio Influence on the current rise time and thus on the way in can be taken. The sinking-in is not possible due to the layer-height of the composite material as a limiting factor a high level of attention was paid to contacting. Since the resin is absorbed by the effect of the electrode force is not deformed, the sinking path must be adapted to the pin height protruding from the layer. By using different capacitors and varied combination pulse sequences (see Figure 2) consisting of an initial pulse (I) for surfaceactivation and a press pulse (II) for introducing the necessary joining energy, specific sinking paths could be set at an interval of 0.15 to 0.75 mm. Figure 3 shows a macrosection of the mixed connection after the joining process. The combination of two thermally coupled single pulses /3/ with current rise times of 0.51 ms also made it possible to significantly reduce the tendency to splatter and to reduce the time previously required within the scope of the project with inverter and
CD single pulse technique by 90 %. The short welding time and the associated low heat input during the process is seen as a clear advantage for the future use of carbon fibers.
Literature reference:/1/Lotte, J.: Entwicklung eines alternativen Fügever-
fahrens zur wirtschaftlichen und prozesssicheren Her-
stellung von faserverstärkten Kunststoff-/Metallhybrid-
strukturen auf Basis des Widerstandsschweißverfahrens
mittels integrierter metallischer Inserts. Aachen, RWTH
Aachen, Institut für Schweißtechnik und Fügetechnik
(ISF), 2017 (Forschungsvorhaben IGF-Nr.: 19,466 N) /2/Rusch, H.-J., Stocks, N.: KE-Mehr-Puls-Schweißen
von Anschweißmuttern auf 22MnB5 + AS150. Oyten,
KAPKON GmbH, Fügetechnisches Versuchszentrum,
2018 (Forschungsbericht)
/3/Stocks, N.: Thermische Kopplung beim Mehr-Puls-
Schweißen. In: Schweißzeit (2018), Nr. 1/18
Nicolas Stocks [email protected]
Kapkon GmbH - Max-Planck-Str. 23 - D-32107 Bad Salzuflen Tel.: +49 (0) 52 22 98 36 50 - E-Mail: [email protected] - Internet: www.kapkon.de
Combi-pulse sequence
Figure 1Snapshot of the inserted joining parts before the welding process
Figure 3Joined material combination of metallic insert and fibre-reinforced plastic
Figure 2temporal course of the current of a combination pulse sequence
time in ms
curre
nt in
kA
Axel.Schneider
Rechteck
Axel.Schneider
Rechteck
Axel.Schneider
Rechteck
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