ABSTRACT
The authors would like to make the following corrections about the published paper [...].
ABSTRACT
This study reports on the development of a novel polymer processing approach that combines low-temperature (LT) processing and fibre direct compounding (FDC) to reduce the thermal stress on thermosensitive components that occurs during compounding and subsequent injection moulding (IM). Composites based on polyamide 6 (PA6) and cellulose fibres (CeF) were prepared using an LT-FDC process and in parallel with a conventional approach using a twin-screw extruder and IM. The morphological, optical, thermal, and mechanical properties of the prepared samples were investigated using optical microscopy (OM), differential scanning calorimetry (DSC), colorimetry, dynamic mechanical analysis (DMA) and tensile tests. Composites prepared using LT-FDC exhibited worse fibre dispersion but lower fibre degradation. In comparison to neat PA6, the LT-FDC composites had increased tensile modulus (Et) and storage modulus (E') at 120 °C by up to 32% and 50%, respectively, while the tensile strength (σm) decreased by 20%.
ABSTRACT
Thermoplastic composites (TPCs) are predestined for use in lightweight structures, especially for high-volume applications. In many cases, joining is a key factor for the successful application of TPCs in multi-material systems. Many joining processes for this material group are based on warm forming the joining zone. This results in a change of the local material structure characterised by modified fibre paths, as well as varying fibre contents, which significantly influences the load-bearing behaviour. During the forming process, many different phenomena occur simultaneously at different scales. In this paper, the deformation modes and flow mechanisms of TPCs during forming described in the literature are first analysed. Based on this, three different joining processes are investigated: embedding of inserts, moulding of contour joints, and hotclinching. In order to identify the phenomena occurring in each process and to describe the characteristic resulting material structure in the joining zones, micrographs as well as computed tomography (CT) analyses are performed for both individual process stages and final joining zones.
ABSTRACT
As lightweight design gains more and more attention, time and cost-efficient joining methods such as clinching are becoming more popular. A clinch point's quality is usually determined by ex situ destructive analyses such as microsectioning. However, these methods do not yield the detection of phenomena occurring during loading such as elastic deformations and cracks that close after unloading. Alternatively, in situ computed tomography (in situ CT) can be used to investigate the loading process of clinch points. In this paper, a method for in situ CT analysis of a single-lap shear test with clinched metal sheets is presented at the example of a clinched joint with two 2 mm thick aluminum sheets. Furthermore, the potential of this method to validate numerical simulations is shown. Since the sheets' surfaces are locally in contact with each other, the interface between both aluminum sheets and therefore the exact contour of the joining partners is difficult to identify in CT analyses. To compensate for this, the application of copper varnish between the sheets is investigated. The best in situ CT results are achieved with both sheets treated. It showed that with this treatment, in situ CT is suitable to properly observe the three-dimensional deformation behavior and to identify the failure modes.
ABSTRACT
Clinching continuous fibre reinforced thermoplastic composites and metals is challenging due to the low ductility of the composite material. Therefore, a number of novel clinching technologies has been developed specifically for these material combinations. A systematic overview of these advanced clinching methods is given in the present paper. With a focus on process design, three selected clinching methods suitable for different joining tasks are described in detail. The clinching processes including equipment and tools, observed process phenomena and the resultant material structure are compared. Process phenomena during joining are explained in general and compared using computed tomography and micrograph images for each process. In addition the load bearing behaviour and the corresponding failure mechanisms are investigated by means of single-lap shear tests. Finally, the new joining technologies are discussed regarding application relevant criteria.
