University of Twente Student Theses


The effects of overlap area and surface roughness on metal-composite friction spot weld joints

Meurs, J. van (2015) The effects of overlap area and surface roughness on metal-composite friction spot weld joints.

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Abstract:Previous studies involving friction spot welding of aluminum 7075-T6 and glass fiber reinforced polyphenylene sulfide (PPS) came across a number of inconsistencies in the welding interface after separating them by means of a lap shear tensile test. The interfaces appeared to transition from fully melted and bound to the aluminum to a barely melted and only weakly bound to the aluminum. Furthermore, varying amounts of resin were found to be stuck to the aluminum surface after separation, suggesting a bond strength highly inconsistent over the entire interface. This study aimed to investigate the influence of these appearing transition areas by varying the surface area of the welding interface. The transition area of the PPS was proven to have a negative influence on the bond strength, 10.9MPa average for samples without transition area to 9.34MPa average with transition area. The PPS resin stuck to the aluminum appeared to have a positive influence on the bond strength, but not nearly as much as indicated by previous work. Furthermore, the effect of surface roughness of the aluminum on bond strength was investigated by compressing the aluminum with P60 sanding paper before welding. The resulting bond strengths of 9.13MPa average were very similar to those of the untreated sample, suggesting that a course surface treatment does not improve bond strength.
Item Type:Essay (Bachelor)
Faculty:ET: Engineering Technology
Subject:51 materials science
Programme:Advanced Technology BSc (50002)
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