Characterization of the hybrid joint between AA2024-T3 alloy and thermoplastic composite obtained by oxy-fuel welding (OFW)

Rafael Resende Lucas; Rita de Cássia Mendonça Sales-Contini; Luis Felipe Barbosa Marques; Jonas Frank Reis; Ana Beatriz Ramos Moreira Abrahão; Edson Cocchieri Botelho; Rogério Pinto Mota; Rafael Resende Lucas; Rita de Cássia Mendonça Sales-Contini; Luis Felipe Barbosa Marques; Jonas Frank Reis; Ana Beatriz Ramos Moreira Abrahão; Edson Cocchieri Botelho; Rogério Pinto Mota

doi:10.3934/matersci.2024029

AIMS Materials Science

2024, Volume 11, Issue 3: 585-601. doi: 10.3934/matersci.2024029

Previous Article Next Article

Research article

Characterization of the hybrid joint between AA2024-T3 alloy and thermoplastic composite obtained by oxy-fuel welding (OFW)

Rafael Resende Lucas ^{1
,
,},
Rita de Cássia Mendonça Sales-Contini ²,
Luis Felipe Barbosa Marques ¹,
Jonas Frank Reis ¹,
Ana Beatriz Ramos Moreira Abrahão ³,
Edson Cocchieri Botelho ¹,
Rogério Pinto Mota ¹

1.
São Paulo State University (UNESP), School of Engineering and Sciences, Guaratinguetá, São Paulo 12516-410, Brazil
2.
Aeronautical Structures Laboratory, Technological College of São José dos Campos Prof. Jessen Vidal (FATEC), São José dos Campos, São Paulo 12247-014, Brazil
3.
Electrochemistry and Corrosion Laboratory, Technological College of Pindamonhangaba (FATEC), Pindamonhangaba, São Paulo 12445-010, Brazil

Received: 23 May 2024 Revised: 06 June 2024 Accepted: 13 June 2024 Published: 19 June 2024

Studies on dissimilar materials joining have greatly increased, transitioning from temporary to permanent joining methods. The latter approach is more applicable due to the hybrid structure offering the best properties of the constituent materials, along with the development of new materials and manufacturing procedures. In this study, the AA2024-T3 alloy was treated with plasma electrolytic oxidation (PEO) and a thermoplastic composite/AA2024-T3 hybrid joint was manufactured using oxy-fuel welding (OFW). Morphological aspects, chemical compositions electrochemical and mechanical properties of hybrid composite joints were determined. The results indicated that the joint exhibits a uniform structure. The adhesion between the dissimilar materials reached a strength of 4.2 to 5.2 MPa, with cohesive bonding and without severe degradation of the thermoplastic matrix in some cases. It was observed that PEO treatment decreased the interface shear strength due to the high silicon content presence in the coating. The coatings effectively increased nobility and corrosion resistance, with corrosion rates ranging from 0.0087 to 0.018 mm/year.
- welding,
- aluminum,
- composite,
- PEO,
- characterization
Citation: Rafael Resende Lucas, Rita de Cássia Mendonça Sales-Contini, Luis Felipe Barbosa Marques, Jonas Frank Reis, Ana Beatriz Ramos Moreira Abrahão, Edson Cocchieri Botelho, Rogério Pinto Mota. Characterization of the hybrid joint between AA2024-T3 alloy and thermoplastic composite obtained by oxy-fuel welding (OFW)[J]. AIMS Materials Science, 2024, 11(3): 585-601. doi: 10.3934/matersci.2024029

Related Papers:

Abstract

Studies on dissimilar materials joining have greatly increased, transitioning from temporary to permanent joining methods. The latter approach is more applicable due to the hybrid structure offering the best properties of the constituent materials, along with the development of new materials and manufacturing procedures. In this study, the AA2024-T3 alloy was treated with plasma electrolytic oxidation (PEO) and a thermoplastic composite/AA2024-T3 hybrid joint was manufactured using oxy-fuel welding (OFW). Morphological aspects, chemical compositions electrochemical and mechanical properties of hybrid composite joints were determined. The results indicated that the joint exhibits a uniform structure. The adhesion between the dissimilar materials reached a strength of 4.2 to 5.2 MPa, with cohesive bonding and without severe degradation of the thermoplastic matrix in some cases. It was observed that PEO treatment decreased the interface shear strength due to the high silicon content presence in the coating. The coatings effectively increased nobility and corrosion resistance, with corrosion rates ranging from 0.0087 to 0.018 mm/year.

References

[1]	Barbosa LCM, de Souza SDB, Botelho EC, et al. (2019) Fractographic evaluation of welded joints of PPS/glass fiber thermoplastic composites. Eng Fail Anal 102: 60–68. https://doi.org/10.1016/j.engfailanal.2019.04.032 doi: 10.1016/j.engfailanal.2019.04.032
[2]	Sarma K, Borah MJ, Saha N (2023) Friction stir spot welding: A novel approach to weld polyvinyl chloride. AIP Conf Proc 2825: 040002. https://doi.org/10.1063/5.0171424 doi: 10.1063/5.0171424
[3]	Shashikumar S, Sreekanth M (2024) Investigation on mechanical properties of polyamide 6 and carbon fiber reinforced composite manufactured by fused deposition modeling technique. J Thermoplast Compos Mater 37: 1730–1747. https://doi.org/10.1177/08927057231200006 doi: 10.1177/08927057231200006
[4]	Ye J, Wu W, Gao Y, et al. (2023) Hygrothermal aging effects on fiber-metal-laminates with engineered interfaces. Compos Commun 43: 101721. https://doi.org/10.1016/j.coco.2023.101721 doi: 10.1016/j.coco.2023.101721
[5]	Siddique A, Iqbal Z, Nawab Y, et al. (2023) A review of joining techniques for thermoplastic composite materials. J Thermoplast Compos Mater 36: 3417–3454. https://doi.org/10.1177/08927057221096662 doi: 10.1177/08927057221096662
[6]	Liu Z, Li Y, Liu Y, et al. (2023) Ultrasonic welding of metal to fiber-reinforced thermoplastic composites: A review. J Manuf Process 85: 702–712. https://doi.org/10.1016/j.jmapro.2022.12.001 doi: 10.1016/j.jmapro.2022.12.001
[7]	Tiamiyu A, Badmos A, Odeshi A, et al. (2017) The influence of temper condition on adiabatic shear failure of AA 2024 aluminum alloy. Mater Sci Eng A 708: 492–502. https://doi.org/10.1016/j.msea.2017.10.026 doi: 10.1016/j.msea.2017.10.026
[8]	Zhang G, Wu L, Tang A, et al. (2018) Active corrosion protection by a smart coating based on a MgAl-layered double hydroxide on a cerium-modified plasma electrolytic oxidation coating on Mg alloy AZ31. Corros Sci 139: 370–382. https://doi.org/10.1016/j.corsci.2018.05.010 doi: 10.1016/j.corsci.2018.05.010
[9]	Fioravante I, Nunes R, Acciari H, et al. (2019) Films formed on carbon steel in sweet environments—A review. J Brazil Chem Soc 30: 1341–1349. https://doi.org/10.21577/0103-5053.20190055 doi: 10.21577/0103-5053.20190055
[10]	Lucas R, Gonçalves L, Santos D (2020) Morphological and chemical characterization of oxide films produced by plasma anodization of 5052 aluminum alloy in solution containing sodium silicate and sodium phosphate. Rev Bras Apl Vac Campinas 39: 33–41. https://doi.org/10.17563/rbav.v39i1.1154 doi: 10.17563/rbav.v39i1.1154
[11]	Zhou C, Qian N, Su H, et al. (2022) Effect of energy distribution on the machining efficiency and surface morphology of Inconel 718 nickel-based superalloy using plasma electrolytic polishing. Surf Coat Technol 441: 128506. https://doi.org/10.1016/j.surfcoat.2022.128506 doi: 10.1016/j.surfcoat.2022.128506
[12]	Pezzato L, Gennari C, Franceschi M, et al. (2022) Influence of silicon morphology on direct current plasma electrolytic oxidation process in AlSi10Mg alloy produced with laser powder bed fusion. Sci Rep 12: 14329. https://doi.org/10.1038/s41598-022-18176-x doi: 10.1038/s41598-022-18176-x
[13]	Valentini F, Pezzato L, Dabalà M, et al. (2023) Study of the effect of functionalization with inhibitors on the corrosion properties of PEO-coated additive manufactured AlSi10Mg alloy. J Mater Res Technol 27: 3595–3609. https://doi.org/10.1016/j.jmrt.2023.10.160 doi: 10.1016/j.jmrt.2023.10.160
[14]	Shore D, Wilson J, Matthews A, et al. (2021) Adhesive bond strength of PEO coated AA6060-T6. Surf Coat Technol 428: 127898. https://doi.org/10.1016/j.surfcoat.2021.127898 doi: 10.1016/j.surfcoat.2021.127898
[15]	Lucas R, Marques L, Botelho E, et al. (2024) Experimental design of the adhesion between a PEI/glass fiber composite and the AA1100 aluminum alloy with oxide coating produced via plasma electrolytic oxidation (PEO). Ceramics 7: 596–606. https://doi.org/10.3390/ceramics7020039 doi: 10.3390/ceramics7020039
[16]	Abrahão A, Reis J, Brejão S, et al. (2015) Evaluation of time, current and pressure parameters in electrical resistance welding of PEI/continuous fiber composites: influence on mechanical resistance. Mater 20: 530–543. https://doi.org/10.1590/S1517-707620150002.0053 doi: 10.1590/S1517-707620150002.0053
[17]	Maia G, Souza M, Brito A (2021) A discussion on the parameters of the resistance spot welding process and their influences on the quality of the welded joint using analysis and design of experiments. SAE Technical Paper. https://doi.org/10.4271/2020-36-0180 doi: 10.4271/2020-36-0180
[18]	Faria R (2018) Use of the extended finite element method to predict the strength of hybrid T-joints. Master Thesis. https://recipp.ipp.pt/handle/10400.22/12703
[19]	Robles J, Dubé M, Hubert P, et al. (2022) Repair of thermoplastic composites: An overview. Adv Manuf-Polym Compos Sci 8: 68–96. https://doi.org/10.1080/20550340.2022.2057137 doi: 10.1080/20550340.2022.2057137
[20]	ASTM (2019) Standard test method for apparent shear strength of single-lap-joint adhesively bonded metal specimens by tension loading (metal-to-metal). Available from: https://www.astm.org/d1002-10r19.html.
[21]	Liu G, Lu X, Zhang X, et al. (2022) Improvement of corrosion resistance of PEO coatings on Al alloy by formation of ZnAl layered double hydroxide. Surf Coat Technol 441: 128528. https://doi.org/10.1016/j.surfcoat.2022.128528 doi: 10.1016/j.surfcoat.2022.128528
[22]	Fatimah S, Kamil M, Han D, et al. (2022) Development of anti-corrosive coating on AZ31 Mg alloy subjected to plasma electrolytic oxidation at sub-zero temperature. J Magnes Alloy 10: 1915–1929. https://doi.org/10.1016/j.jma.2021.07.013 doi: 10.1016/j.jma.2021.07.013
[23]	Aliasghari S, Rogov A, Skeldon S, et al. (2020) Plasma electrolytic oxidation and corrosion protection of friction stir welded AZ31B magnesium alloy-titanium joints. Surf Coat Technol 393: 125838. https://doi.org/10.1016/j.surfcoat.2020.125838 doi: 10.1016/j.surfcoat.2020.125838
[24]	Lucas R, Mota R, Abrahão A, et al. (2022) Characterization of oxide coating grown by plasma electrolytic oxidation (PEO) at different times on aluminum alloy AA2024-T3. MRS Commun 12: 266–271. https://doi.org/10.1557/s43579-022-00174-9 doi: 10.1557/s43579-022-00174-9
[25]	Mohedano M, Mingo B, Matykina E, et al. (2021) Effects of pre-anodizing and phosphates on energy consumption and corrosion performance of PEO coatings on AA6082. Surf Coat Technol 409: 126892. https://doi.org/10.1016/j.surfcoat.2021.126892 doi: 10.1016/j.surfcoat.2021.126892
[26]	Qiu X, Tariq N, Qi L, et al. (2019) Effects of dissimilar alumina particulates on microstructure and properties of cold-sprayed alumina/A380 composite coatings. Acta Metall Sin 32: 1449–1458. https://doi.org/10.1007/s40195-019-00917-z doi: 10.1007/s40195-019-00917-z
[27]	Molaei M, Fattah-alhosseini A, Nouri M, et al. (2022) Systematic optimization of corrosion, bioactivity, and biocompatibility behaviors of calcium-phosphate plasma electrolytic oxidation (PEO) coatings on titanium substrates. Ceram Int 48: 6322–6337. https//doi.org/10.1016/j.ceramint.2021.11.175 doi: 10.1016/j.ceramint.2021.11.175
[28]	ASTM (2019) Standard practice for classifying failure modes in fiber-reinforced-plastic (FRP) joints. Available from: https://www.astm.org/d5573-99r19.html.
[29]	Chai Y, Yan J, Wang C, et al. (2023) Effect of electrical parameters on the growth and properties of 7075 aluminum alloy film based on scanning micro-arc oxidation with mesh electrode. J Mater Res Technol 25: 988–998. https://doi.org/10.1016/j.jmrt.2023.06.020 doi: 10.1016/j.jmrt.2023.06.020
[30]	Dias G, Sakundarini N, May C (2021) Mechanical and failure analysis of multi-materials adhesive joining. Int J Integr Eng 13: 160–166. https://doi.org/10.30880/ijie.2021.13.07.019 doi: 10.30880/ijie.2021.13.07.019
[31]	Sánchez-Romate X, Baena L, Jiménez-Suárez A, et al. (2019) Exploring the mechanical and sensing capabilities of multi-material bonded joints with carbon nanotube-doped adhesive films. Compos Struct 229: 111477. https://doi.org/10.1016/j.compstruct.2019.111477 doi: 10.1016/j.compstruct.2019.111477
[32]	Haddou Y, Salem M, Amiri A, et al. (2023) Numerical analysis and optimization of adhesively-bonded single lap joints by adherend notching using a full factorial design of experiment. Int J Adhes Adhes 26: 103482. https://doi.org/10.1016/j.ijadhadh.2023.103482 doi: 10.1016/j.ijadhadh.2023.103482
[33]	Wilson A, Grabowski A, Kustosik K, et al. (2018) Tartaric acid cross-contamination in post-cascade rinses after sulphuric acid anodising (SAA): Effect on adhesive bond strength of AA6060-T6 alloy. Int J Adhes Adhes 81: 30–35. https://doi.org/10.1016/j.ijadhadh.2017.11.004 doi: 10.1016/j.ijadhadh.2017.11.004
[34]	Müller-Pabel M, Agudo J, Gude M (2022) Measuring and understanding cure-dependent viscoelastic properties of epoxy resin: A review. Polym Test 114: 107701. https://doi.org/10.1016/j.polymertesting.2022.107701 doi: 10.1016/j.polymertesting.2022.107701
[35]	Ramgobin A, Fontaine G, Bourbigot S (2019) Thermal degradation and fire behavior of high performance polymers. Polym Rev 59: 55–123. https://doi.org/10.1080/15583724.2018.1546736 doi: 10.1080/15583724.2018.1546736
[36]	Posuvailo V, Imbirovych N, Povstyanoy O, et al. (2023) The state of electrolytic plasma in synthesis of oxide ceramic coatings on the magnesium basis, In: Ivanov V, Pavlenko I, Liaposhchenko O, et al. Advances in Design, Simulation and Manufacturing VI. DSMIE 2023. Lecture Notes in Mechanical Engineering, Cham: Springer, 258–269. https://doi.org/10.1007/978-3-031-32774-2_26
[37]	Fattah-alhosseini A, Chaharmahali R, Alizad S, et al. (2023) Corrosion behavior of composite coatings containing hydroxyapatite particles on Mg alloys by plasma electrolytic oxidation: A review. J Magnes Alloy 11: 2999–3011. https://doi.org/10.1016/j.jma.2023.09.003 doi: 10.1016/j.jma.2023.09.003
[38]	Xhanari K, Finšgar M (2019) Organic corrosion inhibitors for aluminum and its alloys in chloride and alkaline solutions: A review. Arab J Chem 12: 4646–4663. https://doi.org/10.1016/j.arabjc.2016.08.009 doi: 10.1016/j.arabjc.2016.08.009
[39]	Gobara M, Baraka A, Akid R, et al. (2020) Corrosion protection mechanism of Ce⁴⁺/organic inhibitor for AA2024 in 3.5% NaCl. RSC Adv 10: 2227–2240. https://doi.org/10.1039/C9RA09552G doi: 10.1039/C9RA09552G
[40]	Zamani P, Valefi Z, Jafarzadeh K (2022) Comprehensive study on corrosion protection properties of Al₂O₃, Cr₂O₃ and Al₂O₃–Cr₂O₃ ceramic coatings deposited by plasma spraying on carbon steel. Ceram Int 48: 1574–1588. https://doi.org/10.1016/j.ceramint.2021.09.237 doi: 10.1016/j.ceramint.2021.09.237

Reader Comments

Your name:*

Email:*
© 2024 the Author(s), licensee AIMS Press. This is an open access article distributed under the terms of the Creative Commons Attribution License (http://creativecommons.org/licenses/by/4.0)