Study on the durability of ultrasonically welded carbon fiber reinforced PA6 to AA6061 aluminum alloy joints
In this study, 6061 aluminum alloy (AA6061) and carbon fiber reinforced PA6 (CF/PA6) hybrid structure was fabricated using ultrasonic welding. The AA6061 was modified by KH550 silane coupling agent (SCA), and a PA6 interlayer was prepared on the AA6061 surface as the energy director (ED). The introd...
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| Format: | Article |
| Language: | English |
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Elsevier
2025-09-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425021015 |
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| author | Haipeng Zhou Yilong Zhang Yufan Cai Yuanduo Yang Sansan Ao Yang Li |
| author_facet | Haipeng Zhou Yilong Zhang Yufan Cai Yuanduo Yang Sansan Ao Yang Li |
| author_sort | Haipeng Zhou |
| collection | DOAJ |
| description | In this study, 6061 aluminum alloy (AA6061) and carbon fiber reinforced PA6 (CF/PA6) hybrid structure was fabricated using ultrasonic welding. The AA6061 was modified by KH550 silane coupling agent (SCA), and a PA6 interlayer was prepared on the AA6061 surface as the energy director (ED). The introduction of SCA enhanced the chemical bonding between AA6061 and CF/PA6, forming plenty of Al–O–Si chemical bonds at the welding interface. During the ultrasonic welding process, the molten resin thoroughly wetted the aluminum alloy surface, forming a strong mechanical interlocking. The maximum tensile-shear strength of the AA6061-CF/PA6 ultrasonically welded joint was 30.2 MPa, and the interfacial failure mode was mixed failure. Afterward, the durability of AA6061-CF/PA6 ultrasonically welded joints was investigated from three aspects: post welding heat treatment (PWHT), thermal cycling shock, and salt spray test. The AA6061-CF/PA6 hybrid joints maintained a tensile-shear strength around 30 MPa for different PWHT temperatures, and over 20 MPa after 12 thermal cycles and 15 days of salt spray test. |
| format | Article |
| id | doaj-art-3ecb026b61cf403498a0e45afaf99ea6 |
| institution | Kabale University |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-09-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-3ecb026b61cf403498a0e45afaf99ea62025-08-23T04:48:35ZengElsevierJournal of Materials Research and Technology2238-78542025-09-01382854286410.1016/j.jmrt.2025.08.145Study on the durability of ultrasonically welded carbon fiber reinforced PA6 to AA6061 aluminum alloy jointsHaipeng Zhou0Yilong Zhang1Yufan Cai2Yuanduo Yang3Sansan Ao4Yang Li5School of Materials Science and Engineering, Tianjin University, Tianjin, 300354, ChinaZhejiang Zhenbo Precision Machinery Co., Ltd., Wenzhou, 325604, ChinaSchool of Materials Science and Engineering, Tianjin University, Tianjin, 300354, ChinaSchool of Materials Science and Engineering, Tianjin University, Tianjin, 300354, ChinaSchool of Materials Science and Engineering, Tianjin University, Tianjin, 300354, ChinaSchool of Materials Science and Engineering, Tianjin University, Tianjin, 300354, China; Corresponding author.In this study, 6061 aluminum alloy (AA6061) and carbon fiber reinforced PA6 (CF/PA6) hybrid structure was fabricated using ultrasonic welding. The AA6061 was modified by KH550 silane coupling agent (SCA), and a PA6 interlayer was prepared on the AA6061 surface as the energy director (ED). The introduction of SCA enhanced the chemical bonding between AA6061 and CF/PA6, forming plenty of Al–O–Si chemical bonds at the welding interface. During the ultrasonic welding process, the molten resin thoroughly wetted the aluminum alloy surface, forming a strong mechanical interlocking. The maximum tensile-shear strength of the AA6061-CF/PA6 ultrasonically welded joint was 30.2 MPa, and the interfacial failure mode was mixed failure. Afterward, the durability of AA6061-CF/PA6 ultrasonically welded joints was investigated from three aspects: post welding heat treatment (PWHT), thermal cycling shock, and salt spray test. The AA6061-CF/PA6 hybrid joints maintained a tensile-shear strength around 30 MPa for different PWHT temperatures, and over 20 MPa after 12 thermal cycles and 15 days of salt spray test.http://www.sciencedirect.com/science/article/pii/S2238785425021015Carbon fiber reinforced thermoplasticAluminum alloyUltrasonic weldingMechanical propertyDurability |
| spellingShingle | Haipeng Zhou Yilong Zhang Yufan Cai Yuanduo Yang Sansan Ao Yang Li Study on the durability of ultrasonically welded carbon fiber reinforced PA6 to AA6061 aluminum alloy joints Journal of Materials Research and Technology Carbon fiber reinforced thermoplastic Aluminum alloy Ultrasonic welding Mechanical property Durability |
| title | Study on the durability of ultrasonically welded carbon fiber reinforced PA6 to AA6061 aluminum alloy joints |
| title_full | Study on the durability of ultrasonically welded carbon fiber reinforced PA6 to AA6061 aluminum alloy joints |
| title_fullStr | Study on the durability of ultrasonically welded carbon fiber reinforced PA6 to AA6061 aluminum alloy joints |
| title_full_unstemmed | Study on the durability of ultrasonically welded carbon fiber reinforced PA6 to AA6061 aluminum alloy joints |
| title_short | Study on the durability of ultrasonically welded carbon fiber reinforced PA6 to AA6061 aluminum alloy joints |
| title_sort | study on the durability of ultrasonically welded carbon fiber reinforced pa6 to aa6061 aluminum alloy joints |
| topic | Carbon fiber reinforced thermoplastic Aluminum alloy Ultrasonic welding Mechanical property Durability |
| url | http://www.sciencedirect.com/science/article/pii/S2238785425021015 |
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