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Ultrasonic spot welding of carbon fiber reinforced epoxy composites to aluminum: mechanical and electrochemical characterization

The mechanical and electrochemical behavior of ultrasonic spot welded hybrid joints, made of AA5754 aluminum and carbon fiber reinforced epoxy with a co-cured thermoplastic surface layer, was studied. The effect of the welding parameters (energy and force) and the thickness of a thermoplastic film, applied as an upper ply in the composite lay-up, on the development of adhesion strength, was investigated. The best mechanical results were obtained when the welding parameters were able to achieve a large bonding area of mechanical interlocking between naked carbon fibers and aluminum and a better load distribution. The electrochemical results excluded the possibility of galvanic corrosion between aluminum and composite adherends thanks to the insulating action provided by the thermoplastic film.

» Author: Francesca Lionetto, Claudio Mele, Paola Leo, Sonia D'Ostuni, Frank Balle, Alfonso Maffezzoli

» Reference: Composites Part B: Engineering, Volume 144

» Publication Date: 01/07/2018

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This project has received funding from the European Union Seventh Framework Programme (FP7/2007-2013) under grant agreement n° [609203].

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