Design and Experimental Concept for Dissimilar Ultrasonic Welding Joints for Aluminum Alloy to Glass-Fiber-Reinforced Polymer Tubes
This conceptual study explores ultrasonic welding (UW) for creating joints between aluminum alloy A5052-H32 and glass-fiber-reinforced polymer (GFRP) cylindrical tubes, capitalizing on the method’s advantages, such as low energy requirements, minimal heat-affected zones, and direct energy transfer to the weld interface. The research, conducted by the group with extensive expertise in solid-state joining and material deformation under extreme conditions, responds to the growing demand for reliable, fast, and cost-effective joining technologies. The proposed hybrid-UW technique introduces gradient functions at the joint interface, aiming to enhance the performance of Al/GFRP dissimilar joints. The manuscript not only outlines the technical approach and experimental methods employed but also highlights the distinctive aspects of the proposed technology. In addition to detailing the materials used and the design considerations for the ultrasonic welder’s horn and anvil, the study provides a glimpse into the practical implementation of the proposed hybrid- UW technique. The limited joints made during the experimental phase serve as a proof-of-concept for the feasibility and potential effectiveness of the approach.
The demand for innovative joining technologies capable of joining dissimilar materials with varying properties has surged recently. Lightweight aluminum alloys, known for their structural advantages, and glass-fiber-reinforced polymer (GFRP) composites, prized for their high strength-to-weight ratio, present a compelling combination for diverse industrial applications. Joining these materials, however, remains a challenge, and it is this challenge that motivated the current study. This research is based on a comprehensive understanding of solid-state joining techniques, with a particular emphasis on ultrasonic welding (UW). The process of joining materials without the fusion of heat aligns seamlessly with the group’s expertise (Shin et al., 2016). Over the years, the researchers have significantly contributed to the field, exploring various materials’ deformation behaviors and developing novel joining techniques under extreme conditions (Shin et al., 2008; Shin & Jung, 2008; Shin, 2014, Shin & De Leon, 2015, Shin & De Leon, 2017, Chen et al., 2016). These conditions include high velocity and pressure, cryogenic temperatures, mechanical property testing, and high current conditions, making the researchers’ experience different from the conventional studies in the field.
The industry’s pressing need for dependable, efficient, and reasonably priced joining technologies designed for construction including fiber-reinforced polymer materials is what encouraged this research. Although mechanical joining techniques such as clinching (Zhang et al., 2016) and self-pierce riveting (Mandel & Krüger, 2012; Lambiase & Ko, 2017) facilitate quick assembly without requiring initial hole drilling (Ucsnik et al., 2010), the problem is that fasteners are prone to corrosion and their mass adds structural weight (Tan et al., 2015; Huang et al., 2013). On the contrary, adhesive bonding has disadvantages such as expensive costs, careful surface preparation, and long cure times even though it works well (Farahani & Dubé, 2017; Lionetto et al., 2017). Appropriate adhesion qualities are dependent on a temperature- and time- controlled crosslinking process (Arenas et al., 2013). Moreover, there are disadvantages to this technology, including the short lifespan of adhesive joints and the release of hazardous compounds into the environment (Lambiase et al., 2016; Pramanik et al., 2017).
Current research worldwide is addressing this need, but the group’s advantage lies in the researchers’ experience in solid-state joining, especially with dissimilar materials. Ultrasonic welding, chosen as the primary approach, offers distinct advantages, such as low welding energy requirements and minimal heat-affected zones (Shin & De Leon, 2017). In contrast to other techniques like resistance spot welding, UW and its hybrid variations possibly avoided the liquid phase reactions and directed energy precisely onto the weld interface (De Leon & Shin, 2017; De Leon & Shin, 2023; De Leon & Shin, 2022). This study builds upon the researchers’ extensive knowledge and skills gained for several decades in the deformation behaviors of materials and the development of joining techniques under extreme conditions. The integration of ultrasonic welding into the group, extending even to the joining of high- temperature superconducting tapes, showcases the versatility of this technique (Shin et al., 2016; De Leon & Shin, 2020; Shin et al., 2020). The researchers’ past contributions, such as investigations into dissimilar friction stir spot welding of metallic glass to lightweight crystalline metals (Shin, 2014) and ultrasonic spot welding of A5052-H32 alloy sheets (Shin & De Leon, 2017), mark steps towards addressing similar challenges. The current study, however, distinguishes itself by investigating the intricate details of ultrasonic welding joints between aluminum alloys and GFRP composites.
The remaining sections of this manuscript will present the technical approach, methods, and experimental, and future industry integration of the study, offering a comprehensive exploration of dissimilar ultrasonic welding joints for aluminum alloy to GFRP tubes. Through this study, the researchers aim to present not only a novel contribution to the field but also a potential breakthrough for industrial applications in the near future.
