Abstract

There is an increasing need for joining technologies of resin matrix composites and metals, in which resistance welding is one of the most promising methods. In this work, the resistance welding of 6063Al alloy and CF/epoxy laminate was realized through designing the thermoplastic layer on the surface of the base material. The welding process was conducted under different welding times (t_w) in this research, while porous stainless steel (SS) mesh was selected as a heating implant. The microstructure of the welding interface formed at different t_w was characterized by scanning electron microscopy (SEM), and the characteristic area showed a strong correlation with t_w. The results of mechanical strength of the welding joint were obtained by tensile lap shear strength (LSS) test, which indicated that the LSS can reach a maximum value of 19.18 MPa when welding time (t_w) was 6 mins. To further understand the joint formation process and strength changes law, the evolution process of the welding interface was described in detail according to the temperature distribution simulated by COMSOL. This work provided a technical foundation for large-area surface thermal plasticization in thermosetting composite materials and metals, and then achieve fusion bonding.

摘要

对树脂基复合材料和金属的连接技术的需求日益增加，其中电阻焊是最有前途的方法之一。本工作通过设计基材表面的热塑性层实现6063Al合金与CF/环氧树脂层压板的电阻焊接。在本研究中，焊接过程是在不同的焊接时间 ( t _w ) 下进行的，同时选择多孔不锈钢 (SS) 网作为加热植入物。采用扫描电镜（SEM）表征了不同t _w下形成的焊接界面的显微组织，特征面积与t _{w呈强相关性}. 通过拉伸搭接剪切强度（LSS）试验得到了焊接接头的机械强度结果，表明当焊接时间（ t _w）为6 min时，LSS可以达到最大值19.18 MPa 。为进一步了解接头形成过程和强度变化规律，根据 COMSOL 模拟的温度分布，详细描述了焊接界面的演化过程。该工作为热固性复合材料和金属的大面积表面热塑化，进而实现熔接提供了技术基础。