Abstract
In the present work, thermoset carbon fiber-reinforced polymer (CFRP) was spot joined to magnesium alloy AZ31B by a friction self-piercing riveting (F-SPR) process. Lap shear tensile and cross-tension testing were used to evaluate the mechanical joint performance. An average lap shear tensile load of 5.18 kN was achieved, while an average of 2.81 kN was found from cross-tension testing. All F-SPR samples showed pull-out of AZ31B after mechanical testing, indicating good mechanical interlocking between the steel rivet and AZ31B. Corrosion potential was measured for each material to establish the galvanic corrosion characteristics. As expected, AZ31B was found to be the most active, while thermoset CFRP was the most noble. The steel rivet fell between the AZ31B (active) and the thermoset CFRP (noble). Salt fog corrosion testing (ASTM B-117) was performed to evaluate the corrosion performance of the uncoated F-SPR joint. With up to 200 h of exposure, the post-corroded F-SPR joint integrity retained 81.2% of the preexposure F-SPR joint strength with AZ31B pull-out failure mode. From cross-sectional analysis of the F-SPR joint, extensive corrosion of AZ31B was observed at the joint and other exposure areas. However, steel rivet was not significantly corroded potentially due to sacrificial anode effect by which AZ31B corroded first in the galvanic couple.
| Original language | English |
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| Title of host publication | Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability |
| Publisher | American Society of Mechanical Engineers |
| ISBN (Electronic) | 9780791884263 |
| DOIs | |
| State | Published - 2020 |
| Event | ASME 2020 15th International Manufacturing Science and Engineering Conference, MSEC 2020 - Virtual, Online Duration: Sep 3 2020 → … |
Publication series
| Name | ASME 2020 15th International Manufacturing Science and Engineering Conference, MSEC 2020 |
|---|---|
| Volume | 2 |
Conference
| Conference | ASME 2020 15th International Manufacturing Science and Engineering Conference, MSEC 2020 |
|---|---|
| City | Virtual, Online |
| Period | 09/3/20 → … |
Funding
One critical challenge to the development of multi-material vehicles is how to join the physical and chemical dissimilarities of different materials, such as metals to polymer composites. Limited research has focused on joining metal to polymer composites by laser welding [8]; resistance spot welding with silane surface treatment [9]; solid-state [10,11,12], ultrasonic [13], and mechanical fastening [14]; and adhesive bonding and weld bonding [15]. Most previous studies considered how to weld or join Al alloys to thermoplastics or advanced ultrahigh- 1 Contact author: [email protected] Notice: This manuscript has been authored by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan). This research was funded by the US Department Energy’s Vehicle Technology Offices as part of the Joining Core Program. Oak Ridge National Laboratory (ORNL) is managed by UT-Battelle, LLC for the US Department of Energy under Contract DE-AC05-00OR22725.
Keywords
- AZ31B
- Carbon fiber-reinforced polymer
- Corrosion performance
- Dissimilar material joining
- Friction self-piercing riveting
- Mechanical strength