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Effect of PA6 coating on the ultrasonic welding of CF/PA66 to 6061 aluminum alloy

  • Composites & nanocomposites
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Abstract

Carbon fiber-reinforced thermoplastic composites (CFRTPs) are widely used in industrial manufacturing due to their excellent mechanical properties, and the joining of lightweight metal/CFRTP hybrid structure has gained more attention. Ultrasonic welding is a promising method for achieving metal/CFRTP dissimilar joining. In this study, 6061 aluminum alloy and carbon fiber-reinforced polyamide-66 (CF/PA66) were ultrasonically welded by preparing a PA6 coating on the surface of aluminum sheet as an interlayer. This paper investigates the effects of welding parameters on the joint mechanical property. Optimized process parameters (welding force 600 N, amplitude 60% and welding time 0.6 s) are determined by experiments. The effects of the thickness and crystallinity of the PA6 coating on the joint strength are investigated. The results show that there exists an optimal coating thickness that maximizes the joint strength. Low crystallinity of the coating contributes to high joint strength. Mixed failure mode (adhesive failure, substrate failure and cohesive failure) is observed based on the analysis on the fracture surface.

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Funding

This work was supported by the National Natural Science Foundation of China (No. 52075375).

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Authors and Affiliations

  1. School of Materials Science and Engineering, Tianjin University, Tianjin, 300354, China

    Ruoya Shi, Zeguang Liu, Sansan Ao, Zhen Luo & Yang Li

  2. Tianjin Key Laboratory of Advanced Joining Technology, Tianjin University, Tian, 30354, China

    Sansan Ao, Zhen Luo & Yang Li

  3. International Institute for Innovative Design and Intelligent Manufacturing of Tianjin University in Zhejiang, Shaoxing, 31200, China

    Yang Li

  4. College of Aeronautical Engineering, Civil Aviation University of China, Tianjin, 300300, China

    Weidong Liu

Authors
  1. Ruoya Shi
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  2. Zeguang Liu
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  3. Weidong Liu
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  4. Sansan Ao
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  5. Zhen Luo
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  6. Yang Li
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Contributions

All authors contributed to the study conception and design. Material preparation, data collection and analysis were performed by RS, ZL, WL, SA, ZL and YL. The first draft of the manuscript was written by RS and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Yang Li.

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The authors declare no competing interests.

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Handling Editor: Naiqin Zhao.

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Shi, R., Liu, Z., Liu, W. et al. Effect of PA6 coating on the ultrasonic welding of CF/PA66 to 6061 aluminum alloy. J Mater Sci 59, 2328–2339 (2024). https://doi.org/10.1007/s10853-023-09323-4

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  • DOI: https://doi.org/10.1007/s10853-023-09323-4

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