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Microstructure
New Airbus employs innovative technologies that result in improved fuel efficiency, reduced emissions
and lower noise levels.
Substitution of conventional materials by plastics leading to weight savings.
Principles of the Process
Welding in overlap configuration.
Microstructure of a FSpW on 3 mm Poly (methyl-methacrylate) – PMMA - casting sheets (500 rpm, 5,5 s, 4 mm of plunge depth).
Local Mechanical Properties
Global Mechanical Properties
Failure Mechanisms under Shear Loading
Specimen with Fracture in the Upper Plate.
FSpW and the Current State-of-the-Art
The crack initiates in the shrinkage defect (hook) and propagates through the interface of Stir Zone and Thermal Affected Zone.
• Preliminary results showingequal or better results incomparison to other joiningtechniques .
Maximum weld strengths of PMMA joints welded by different techniques.
Microhardness map distribution and weld regions: Thermal Affected Zone, Stir Zone and Base Material.
Lap-shear Strength of two FSpW specimens welded with different plunge
depths (500 rpm, 5,5 s).
A nominal circular area,
calculated from the sleeve’s
external diameter was
considered.
RPS 100 – Friction Spot Welding Machine.
FSpW Titanium tools.
Welding Equipment and Tools
Specimen with Fracture in the Lower Plate.
Friction Spot Welding (FSpW) of PMMAP.H.F Oliveira, Federal University of Sao Carlos, Department of Materials EngineeringS. Amancio, Helmholtz-Zentrum Geesthacht, Institute of Materials, Materials Mechanics, Solid State Joining Processes, Advanced Polymer-Metal Hybrid StructuresJ. F. dos Santos, Helmholtz-Zentrum Geesthacht, Institute of Materials, Materials Mechanics, Solid State Joining ProcessesE. Hage Jr., Federal University of Sao Carlos, Department of Materials Engineering
Motivation
Increased selection of thermoplastics to reduce weight and emissions of modern vehicles and airplanes Design of larger parts with complex geometries requiring the use of welding techniques FSpW of metals present short welding cycles, high energy efficiency, reduced process steps and environmental compatibility. FSpW of thermoplastic is a new R&D field in the science and technology of welding and joining
Friction Spot Joining
FSpW of PMMA – Results and Discussion
Final RemarksThe feasibility of FSpW on thermoplastics was successfully demonstrated. Strong friction spot welds on PMMA were obtainedJoint strength can be further improved through process optimization. Additional investigation is required for a better comprehension of the process-properties relationships and bonding mechanisms in FSpW
Helmholtz-Zentrum Geesthacht • Max-Planck-Straße 1 • 21502 Geesthacht • Phone +49 (0)4152 87-2066 • Fax +49 (0)4152 87-2033 • www.hzg.deContact: Prof. Dr.-Ing. S. Amancio – [email protected]
