Optimization and microstructural study of friction riveted carbon-Kevlar and aluminum joints for aerospace applications
Abstract Friction riveting has emerged as a promising candidate for joining metals to polymers, as it is energy efficient, fast and environmentally friendly without material wastage. The joining of hybrid carbon-Kevlar polymer matrix composites with AA 7075 aluminium alloy is investigated in the cur...
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Nature Portfolio
2025-02-01
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| Series: | Scientific Reports |
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| Online Access: | https://doi.org/10.1038/s41598-025-89357-7 |
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| author | Nagarajan Jawahar Vignesh Rajesh Jesudoss Hynes Navasingh Shenbaga Velu Pitchumani Angela Jennifa Sujana Jesudoss Piotr Nieslony Venkatachalam Gopalan Krzysztof Stebel Radosław Jasiński Maciej Zdanowski Jana Petru Robert Čep |
| author_facet | Nagarajan Jawahar Vignesh Rajesh Jesudoss Hynes Navasingh Shenbaga Velu Pitchumani Angela Jennifa Sujana Jesudoss Piotr Nieslony Venkatachalam Gopalan Krzysztof Stebel Radosław Jasiński Maciej Zdanowski Jana Petru Robert Čep |
| author_sort | Nagarajan Jawahar Vignesh |
| collection | DOAJ |
| description | Abstract Friction riveting has emerged as a promising candidate for joining metals to polymers, as it is energy efficient, fast and environmentally friendly without material wastage. The joining of hybrid carbon-Kevlar polymer matrix composites with AA 7075 aluminium alloy is investigated in the current work. The multi-material joints were subjected to mechanical tests such as the T-pull tensile test and the lap shear pull-out test. The tensile load capacity and the shear pull-out capacity were 5.83 kN and 2.95 kN respectively. The process parameters involved were optimised by applying a hybrid Taguchi-Grey relation analysis. The optimum process parameters were 6000 rpm riveting speed, 0.2 MPa reaming pressure and 6 s reaming time. Optimization showed that the speed of the rivet is the most influential parameter in determining the strength of the joint and it is followed by friction time and pressure. Microstructural investigations showed the formation of different flow patterns and structures in bonding performance between carbon fibre and Kevlar fibre, that are involved in increasing the strength of the joints formed. |
| format | Article |
| id | doaj-art-7c7eb77627a84141bf56d6082983e95a |
| institution | DOAJ |
| issn | 2045-2322 |
| language | English |
| publishDate | 2025-02-01 |
| publisher | Nature Portfolio |
| record_format | Article |
| series | Scientific Reports |
| spelling | doaj-art-7c7eb77627a84141bf56d6082983e95a2025-08-20T02:59:35ZengNature PortfolioScientific Reports2045-23222025-02-0115111710.1038/s41598-025-89357-7Optimization and microstructural study of friction riveted carbon-Kevlar and aluminum joints for aerospace applicationsNagarajan Jawahar Vignesh0Rajesh Jesudoss Hynes Navasingh1Shenbaga Velu Pitchumani2Angela Jennifa Sujana Jesudoss3Piotr Nieslony4Venkatachalam Gopalan5Krzysztof Stebel6Radosław Jasiński7Maciej Zdanowski8Jana Petru9Robert Čep10Department of Mechanical Engineering, SRM Madurai College for Engineering and TechnologyFaculty of Mechanical Engineering, Opole University of TechnologyCentre for Advanced Materials and Innovative Technologies, Vellore Institute of TechnologyDepartment of Artificial Intelligence and Data Science, Mepco Schlenk Engineering CollegeFaculty of Mechanical Engineering, Opole University of TechnologyCentre for Advanced Materials and Innovative Technologies, Vellore Institute of TechnologyFaculty of Automatic Control, Electronics and Computer Science, Department of Automatic Control and Robotics, Silesian University of TechnologyFaculty of Civil Engineering, Department of Building Structures and Laboratory of Civil Engineering Faculty, Silesian University of TechnologyFaculty of Electrical Engineering, Automatic Control and Computer Science, Opole University of TechnologyDepartment of Machining, Assembly and Engineering Metrology, Mechanical Engineering Faculty, VŠB-Technical University of OstravaDepartment of Machining, Assembly and Engineering Metrology, Mechanical Engineering Faculty, VŠB-Technical University of OstravaAbstract Friction riveting has emerged as a promising candidate for joining metals to polymers, as it is energy efficient, fast and environmentally friendly without material wastage. The joining of hybrid carbon-Kevlar polymer matrix composites with AA 7075 aluminium alloy is investigated in the current work. The multi-material joints were subjected to mechanical tests such as the T-pull tensile test and the lap shear pull-out test. The tensile load capacity and the shear pull-out capacity were 5.83 kN and 2.95 kN respectively. The process parameters involved were optimised by applying a hybrid Taguchi-Grey relation analysis. The optimum process parameters were 6000 rpm riveting speed, 0.2 MPa reaming pressure and 6 s reaming time. Optimization showed that the speed of the rivet is the most influential parameter in determining the strength of the joint and it is followed by friction time and pressure. Microstructural investigations showed the formation of different flow patterns and structures in bonding performance between carbon fibre and Kevlar fibre, that are involved in increasing the strength of the joints formed.https://doi.org/10.1038/s41598-025-89357-7Low-speed friction rivetingCarbon-Kevlar hybrid compositesAA 7075 rivetsT pull-tensile testLap shear pull-out testHybrid Taguchi Grey Relational Analysis |
| spellingShingle | Nagarajan Jawahar Vignesh Rajesh Jesudoss Hynes Navasingh Shenbaga Velu Pitchumani Angela Jennifa Sujana Jesudoss Piotr Nieslony Venkatachalam Gopalan Krzysztof Stebel Radosław Jasiński Maciej Zdanowski Jana Petru Robert Čep Optimization and microstructural study of friction riveted carbon-Kevlar and aluminum joints for aerospace applications Scientific Reports Low-speed friction riveting Carbon-Kevlar hybrid composites AA 7075 rivets T pull-tensile test Lap shear pull-out test Hybrid Taguchi Grey Relational Analysis |
| title | Optimization and microstructural study of friction riveted carbon-Kevlar and aluminum joints for aerospace applications |
| title_full | Optimization and microstructural study of friction riveted carbon-Kevlar and aluminum joints for aerospace applications |
| title_fullStr | Optimization and microstructural study of friction riveted carbon-Kevlar and aluminum joints for aerospace applications |
| title_full_unstemmed | Optimization and microstructural study of friction riveted carbon-Kevlar and aluminum joints for aerospace applications |
| title_short | Optimization and microstructural study of friction riveted carbon-Kevlar and aluminum joints for aerospace applications |
| title_sort | optimization and microstructural study of friction riveted carbon kevlar and aluminum joints for aerospace applications |
| topic | Low-speed friction riveting Carbon-Kevlar hybrid composites AA 7075 rivets T pull-tensile test Lap shear pull-out test Hybrid Taguchi Grey Relational Analysis |
| url | https://doi.org/10.1038/s41598-025-89357-7 |
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