One way of addressing environmental problems is to increase the use of light-weight materials in automobiles, such as the multi-material structure, which improves fuel economy and reduces pollution. However, it is necessary to develop a welding technique to join carbon fibre-reinforced plastic to metals to achieve a multi-material structure. So, this paper aims to shorten the welding time and to clarify the fatigue fracture mechanism of shear type friction stir spot welding joint between aluminium alloy and CFRP experimentally and analytically. As a result, the static and fatigue strength of the joint improved as the welding time increased due to the increase of total joint area to increased resin melting.
TranVX, PanJ.Fatigue behavior of dissimilar spot friction welds in lap-shear and cross-tension specimens of aluminum and steel sheets. Int J Fatigue. 2010; 32:1167–1179. doi: 10.1016/j.ijfatigue.2009.12.011
2.
SunYF, FujiiH, TakakiN, Microstructure and mechanical properties of dissimilar Al alloy/steel joints prepared by a flat spot friction stir welding technique. Mater Des. 2013; 47:350–357. doi: 10.1016/j.matdes.2012.12.007
3.
IbrahimI, UematsuY, KakiuchiT, Fatigue behaviour of dissimilar Al alloy/galvanised steel friction stir spot welds fabricated by scroll grooved tool without probe. Sci Tech Weld Join. 2015; 20(8):670–678. doi: 10.1179/1362171815Y.0000000053
4.
LiuFC, LiaoJ, NakataK.Joining of metal to plastic using friction lap welding. Mater Des. 2014; 54:236–244. doi: 10.1016/j.matdes.2013.08.056
5.
LeeSJ, NakamuraH, KawahitoY, Effect of welding speed on microstructural and mechanical properties of laser lap weld joints in dissimilar Al and Cu sheets. Sci Tech Weld Join. 2014; 19(2):670–678. doi: 10.1179/1362171813Y.0000000168
6.
JungKW, KawahitoY, TakahashiM, Laser direct joining of carbon fiber reinforced plastic to zinc-coated steel. Mater Des. 2013; 47:111–118. doi: 10.1016/j.matdes.2012.12.015
7.
TanX, ZhangJ, ShanJ, Characteristics and formation mechanism of porosities in CFRP during laser joining of CFRP and steel. Compos B Eng. 2015; 70:35–43. doi: 10.1016/j.compositesb.2014.10.023
8.
IshiiK, ImanakaM, NakayamaH, Evaluation of the fatigue strength of adhesively bonded CFRP/metal single and single-step double-lap joints. Compos Sci Tech. 1999; 59:1675–1683. doi: 10.1016/S0266-3538(99)00028-7
9.
ZhangK, LiL, DuanY, Experimental and theoretical stress analysis for an interface stress model of single-L adhesive joints between CFRP and aluminum components. Int J Adhes Adhes. 2014; 50:37–44. doi: 10.1016/j.ijadhadh.2013.12.021
10.
SunX, StephensEV, KhaleelMA.Fatigue behaviors of self-piercing rivets joining similar and dissimilar sheet metals. Int J Fatigue. 2007; 29:370–386. doi: 10.1016/j.ijfatigue.2006.02.054
11.
HanL, ChrysanthouA.Evaluation of quality and behaviour of self-piercing riveted aluminium to high strength low alloy sheets with different surface coatings. Mater Des. 2008; 29:458–468. doi: 10.1016/j.matdes.2006.12.020
12.
FrancoGD, FratiniL, PastaA.Analysis of the mechanical performance of hybrid (SPR/bonded) single-lap joints between CFRP panels and aluminum blanks. Int J Adhes Adhes. 2013; 41:24–32. doi: 10.1016/j.ijadhadh.2012.10.008
13.
KimYG, FujiiH, TsumuraT, Three defect types in friction stir welding of aluminum die casting alloy. Mater Sci Eng A. 2006; 415:250–254. doi: 10.1016/j.msea.2005.09.072
14.
LeeWB, JungSB.The joint properties of copper by friction stir welding. Mater Lett. 2004; 58(6):1041–1046. doi: 10.1016/j.matlet.2003.08.014
15.
LeeWB, LeeCY, ChangWS, Microstructural investigation of friction stir welded pure titanium. Mater Lett. 2005; 59(26):3315–3318. doi: 10.1016/j.matlet.2005.05.064
16.
FujiiH, CuiL, TsujiN, Friction stir welding of carbon steels. Mater Sci Eng A. 2006; 429:50–57. doi: 10.1016/j.msea.2006.04.118
17.
MatsushitaM, KitaniY, IkedaR.Development of friction stir welding of high strength steel sheet. Sci Tech Weld Join. 2011; 16(2):181–187. doi: 10.1179/1362171810Y.0000000026
18.
Joy-A-KaS, OgawaY, AkebonoH, Fatigue damage evaluation of friction stir spot welded cross-tension joints under repeated two-step force amplitudes. J Mater Eng Perform. 2015; 24(6):2494–2502. doi: 10.1007/s11665-015-1534-x
19.
LambiaseF, PaolettiA, Di IlioA.Mechanical behaviour of friction stir spot welds of polycarbonate sheets. Int J Adv Manuf Tech. 2015; 80:301–314. doi: 10.1007/s00170-015-7007-4
20.
OliveiraPHF, Amancio-FilhoST, dos SantosJF, Preliminary study on the feasibility of friction spot welding in PMMA. 2010; 64(19):2098–2101.
21.
YusofF, MuhamadMR, MoshwanR, Effect of surface states on joining mechanisms and mechanical properties of aluminum alloy (A5052) and polyethylene terephthalate (PET) by dissimilar friction spot welding. Metals. 2016; 6(5):101. doi: 10.3390/met6050101
22.
OgawaY, XiongY, AkebonoH, Fatigue properties of friction stir welds of treated Al to carbon fibre-reinforced plastic. Sci Tech Weld Join. 2018; 23(1):79–86. doi: 10.1080/13621718.2017.1344453
23.
YuanW, MishraRS, WebbS, Effect of tool design and process parameters on properties of Al alloy 6016 friction stir spot welds. J Mater Proc Tech. 2011; 211(6):972–977. doi: 10.1016/j.jmatprotec.2010.12.014
24.
ZhangZ, YangX, ZhangJ, Effect of welding parameters on microstructure and mechanical properties of friction stir spot welded 5052 aluminum alloy. Mater Des. 2011; 32:4461–4470. doi: 10.1016/j.matdes.2011.03.058
25.
BiliciMK.Application of Taguchi approach to optimize friction stir spot welding parameters of polypropylene. Mater Des. 2012; 35:113–119. doi: 10.1016/j.matdes.2011.08.033
26.
PramanikA, BasakAK, DongY, Joining of carbon fibre reinforced polymer (CFRP) composites and aluminium alloys – a review. Compos A Appl Sci Manuf. 2017; 101:1–29. doi: 10.1016/j.compositesa.2017.06.007
27.
WagnerG, BalleF, EiflerD.Ultrasonic welding of aluminum alloys to fiber reinforced polymers. Adv Eng Mater. 2013; 15:792–803. doi: 10.1002/adem.201300043
28.
LionettoF, BalleF, MaffezzoliA.Hybrid ultrasonic spot welding of aluminum to carbon fiber reinforced epoxy composites. J Mater Process Technol. 2017; 247:289–295. doi: 10.1016/j.jmatprotec.2017.05.002
29.
TanegashimaR, AkebonoH, KatoM, 3-Dimensional observation of the interior fracture mechanism and establishment of cumulative fatigue damage evaluation on spot welded joints using 590 MPa-class steel. Int J Fatigue. 2013; 51:121–131. doi: 10.1016/j.ijfatigue.2012.12.014
30.
Joy-A-KaS, OgawaY, SugetaA, Fatigue fracture mechanism on friction stir spot welded joints using 300 MPa-class automobile steel sheets under constant and variable force amplitude. Proc Mater Sci. 2014; 3:537–543. doi: 10.1016/j.mspro.2014.06.089
