Polymer-Metal Adhesion of Single-Lap Joints Using Fused Filament Fabrication Process: Aluminium with Carbon Fiber Reinforced Polyamide
Source abstract
Abstract
Additive manufacturing (AM) is often used for prototyping; however, in recent years, there have been several final product applications, namely the development of polymer-metal hybrid (PMH) components that have emerged. In this paper, the objective is to characterize the adhesion of single-lap joints between two different materials: aluminium and a polymer-based material manufactured by fused filament fabrication (FFF). Single-lap joints were fabricated using an aluminium substrate with different surface treatments: sandpaper polishing (SP) and grit blasting (GB). Three filaments for FFF were tested: acrylonitrile butadiene styrene (ABS), polyamide (PA), and polyamide reinforced with short carbon fibers (PA + CF). To characterize the behaviour of these single-lap joints, mechanical tension loading tests were performed. The analysis of the fractured surface of the joints aimed to correlate the adhesion performance of each joint with the occurred failure mode. The obtained results show the impact of surface roughness (0.16 < Ra < 1.65 µm) on the mechanical properties of the PMH joint. The ultimate lap shear strength (ULSS) of PMH single-lap joints produced by FFF (1 < ULSS < 6.6 MPa) agree with the reported values in the literature and increases for substrates with a higher surface roughness, remelting of the primer (PA and PA + CF), and higher stiffness of the polymer-based adherent.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Additive Manufacturing and 3D Printing Technologies · Innovations in Concrete and Construction Materials · Additive Manufacturing Materials and Processes
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
IST, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisbon, Portugal
IDMEC, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisbon, Portugal
Funding
FCT—Fundação para a Cíência e Tecnologia
References (89)
Show source-provided references
1. United Nations General Assembly (2015). Transforming Our World: The 2030 Agenda for Sustainable Development, United Nations.
2. European Commission (2019). The European Green Deal, European Comission.
3. European Commission (2020). A New Industrial Strategy for Europe, European Comission.
4. Prospects of Joining Multi-Material Structures10.1063/1.5033165 ↗
5. Joining of Dissimilar Materials10.1016/j.cirp.2015.05.006 ↗
6. Joining of Automotive Sheet Materials by Friction-Based Welding Methods: A Review
7. Quasi-Static Axial Crush Response and Energy Absorption of Composite Wrapped Metallic Thin-Walled Tube10.1007/s40430-022-03449-3 ↗
8. Elmi Hosseini, S.R., Fernandes, F.A.O., Pereira, A.B., and Li, Z. (2022). Welding of Dissimilar Materials in Aerospace Systems, Springer Nature.10.1007/978-3-030-91873-6_13 ↗
9. Fibre Laser Welding of Dissimilar Alloys of Ti-6Al-4V and Inconel 718 for Aerospace Applications10.1007/s00170-010-2791-3 ↗
10. Energy Absorption of Foam-Filled Corrugated Core Sandwich Panels under Quasi-Static Loading
11. Using Phase Change Materials in Clothing10.1177/004051750107100605 ↗
12. Rapid Manufacturing and Rapid Tooling with Layer Manufacturing (LM) Technologies, State of the Art and Future Perspectives10.1016/S0007-8506(07)60206-6 ↗
13. Multi-Objective Design Optimization of Functionally Graded Material for the Femoral Component of a Total Knee Replacement10.1016/j.matdes.2013.06.050 ↗
14. Multiprocess 3D Printing for Increasing Component Functionality10.1126/science.aaf2093 ↗
15. 3-D Printing: The New Industrial Revolution10.1016/j.bushor.2011.11.003 ↗
16. 3D Printing—A New Industrial Revolution
17. Techniques for Joining Dissimilar Materials: Metals and Polymers
18. Gonzales, D.S., and Alvarez, A.G. (2018). Additive Manufacturing Feasibility Study and Technology Demonstration EDA AM—State of the Art and Strategic Report, European Defence Agency.
19. Multiple Material Additive Manufacturing—Part 1: A Review10.1080/17452759.2013.778175 ↗
20. (2021). Additive Manufacturing—General Principles—Fundamentals and Vocabulary (Standard No. ISO/ASTM 52900:2021).
21. Fafenrot, S., Grimmelsmann, N., Wortmann, M., and Ehrmann, A. (2017). Three-Dimensional (3D) Printing of Polymer-Metal Hybrid Materials by Fused Deposition Modeling. Materials, 10.10.3390/ma10101199 ↗
22. AddJoining: A Novel Additive Manufacturing Approach for Layered Metal-Polymer Hybrid Structures10.1016/j.matlet.2018.01.021 ↗
23. Falck, R., dos Santos, J.F., and Amancio-Filho, S.T. (2019). Microstructure and Mechanical Performance of Additively Manufactured Aluminum 2024-T3/Acrylonitrile Butadiene Styrene Hybrid Joints Using an AddJoining Technique. Materials, 12.10.3390/ma12060864 ↗
24. A Review of Melt Extrusion Additive Manufacturing Processes: I. Process Design and Modeling10.1108/RPJ-01-2013-0012 ↗
25. Shrivastava, A. (2018). Introduction to Plastics Engineering, Elsevier.10.1016/B978-0-323-39500-7.00001-0 ↗
26. Langford, W. (2012). Achieving Precise Flow in Fused Deposition Modeling Extruders, Tufts University. Term Paper—Engineering Management.
27. A Review of Melt Extrusion Additive Manufacturing Processes: II. Materials, Dimensional Accuracy, and Surface Roughness10.1108/RPJ-02-2013-0017 ↗
28. An Overview of Fused Deposition Modelling (FDM): Research, Development and Process Optimisation10.1108/RPJ-08-2019-0230 ↗
29. Critical Parameters Influencing the Quality of Prototypes in Fused Deposition Modelling10.1016/S0924-0136(01)00980-3 ↗
30. Van Weeren, R., Agarwala, M., Jamalabad, V.R., Bandyopadhyay, A., Vaidyanathan, R., Langrana, N., Safari, A., Whalen, P., Danforth, S.C., and Ballard, C. (1995, January 7–9). Quality of Parts Processed by Fused Deposition. Proceedings of the International Solid Freeform Fabrication Symposium, Austin, TX, USA.
31. Structural Quality of Parts Processed by Fused Deposition10.1108/13552549610732034 ↗
32. Dey, A., and Yodo, N. (2019). A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics. J. Manuf. Mater. Process., 3.10.3390/jmmp3030064 ↗
33. Improving Dimensional Accuracy of Fused Deposition Modelling Processed Part Using Grey Taguchi Method10.1016/j.matdes.2009.04.030 ↗
34. Kuznetsov, V.E., Solonin, A.N., Urzhumtsev, O.D., Schilling, R., and Tavitov, A.G. (2018). Strength of PLA Components Fabricated with Fused Deposition Technology Using a Desktop 3D Printer as a Function of Geometrical Parameters of the Process. Polymer, 10.10.20944/preprints201803.0036.v1 ↗
35. Effect of Processing Conditions on the Bonding Quality of FDM Polymer Filaments10.1108/13552540810862028 ↗
36. Influence of Fused Deposition Modeling Parameters on the Mechanical Properties of ABS Parts10.1002/pat.4787 ↗
37. Bagsik, A., and Schöppner, V. (2011, January 1–5). Mechanical Properties of Fused Deposition Modeling Parts Manufactured with ULTEM 9085. Proceedings of the 69th Annual Technical Conference of the Society of Plastics Engineers (ANTEC’11), Boston, MA, USA.
38. Magnus, C. (2012). Feasibility Study of Metal to Polymer Hybrid Joinin. [Master’s Thesis, Lappeenranta University of Technology].
39. Troschitz, J., Vorderbrüggen, J., Kupfer, R., Gude, M., and Meschut, G. (2020). Joining of Thermoplastic Composites with Metals Using Resistance Element Welding. Appl. Sci., 10.10.3390/app10207251 ↗
40. Popp, J., Römisch, D., Merklein, M., and Drummer, D. (2022). Joining of CFRT/Steel Hybrid Parts via Direct Pressing of Cold Formed Non-Rotational Symmetric Pin Structures. Appl. Sci., 12.10.3390/app12104962 ↗
41. Petrie, E.M. (2013). Joining Textiles Principles and Applications, Elsevier.
42. Chawla, K.K. (2012). Composite Materials, Springer.10.1007/978-0-387-74365-3 ↗
43. Ebnesajjad, S. (2011). Handbook of Adhesives and Surface Preparation Technology, Applications and Manufacturing, Elsevier.10.1016/B978-1-4377-4461-3.10006-9 ↗
44. Electronic Theory of Adhesion10.1063/1.1709192 ↗
45. Experimental and Theoretical Description of the Electrostatic Component of Adhesion at Polymer/Metal Contacts10.1016/0143-7496(88)90027-9 ↗
46. Adhesion of Polymers10.1016/j.progpolymsci.2009.04.007 ↗
47. Adhesion Phenomena in Bonded Joints10.1016/j.ijadhadh.2012.04.007 ↗
48. Improving the Adhesion of Polyethylene by UV Grafting10.1080/00218460600775815 ↗
49. Microstructural Studies of Interfacial Deformation in Painted Thermoplastic Polyolefins (TPOs)10.1023/A:1020858029040 ↗
50. The Role of Diffusion Phenomena in Polymer-to-Polymer Adhesion10.1002/app.1963.070070207 ↗
51. Causes of Poor Adhesion: Weak Boundary Layers10.1021/ie51403a010 ↗
52. Basic Terms and Definitions in Adhesion10.1134/S1995421208010085 ↗
53. Relationship between Coefficient of Friction and Surface Roughness of Wafer in Nanomachining Process
54. Mechanisms of Interfacial Adhesion in Metal–Polymer Composites—Effect of Chemical Treatment10.1016/j.compositesa.2011.03.019 ↗
55. Integrated Laser-Based Powder Bed Fusion and Fused Filament Fabrication for Three-Dimensional Printing of Hybrid Metal/Polymer Objects
56. Influence of Metal Surface Preparation on Its Surface Profile, Contact Angle, Surface Energy and Adhesion with Glass Fibre Prepreg10.1016/j.ijadhadh.2014.02.006 ↗
57. The Effects of Grit-Blasting on Surface Properties for Adhesion10.1016/S0143-7496(98)00061-X ↗
58. Petrie, E.M. (2007). Handbook of Adhesives and Sealants, McGraw-Hill Education.
59. Theoretical and Experimental Analysis of the Scarf Joint Bonded Structure: Influence of the Adhesive Thickness on the Micro-Mechanical Behavior10.1080/00218469908010485 ↗
60. Duncan, B.C., and Crocker, L.E. (2001). Review of Tests for Adhesion Strength, National Physical Laboratory.
61. Yilmaz, B., Asokkumar, A., Jasiūnienė, E., and Kažys, R.J. (2020). Air-Coupled, Contact, and Immersion Ultrasonic Non-Destructive Testing: Comparison for Bonding Quality Evaluation. Appl. Sci., 10.10.3390/app10196757 ↗
62. Barile, C., Casavola, C., Pappalettera, G., and Vimalathithan, P.K. (2021). Multiparameter Approach for Damage Propagation Analysis in Fiber-Reinforced Polymer Composites. Appl. Sci., 11.10.3390/app11010393 ↗
63. Plating on Acrylonitrile–Butadiene–Styrene (ABS) Plastic: A Review10.1007/s10853-015-9668-7 ↗
64. High Quality Copper-Nickel-Chromium Plating on Plastics: A Continuous Process and Its Challenges
65. Comparative Study of Electroless Ni-p, Cu, Ag, and Cu-Ag Plating on Polyamide Fabrics10.1177/1528083710387176 ↗
66. Giraud, D., Borit, F., Guipont, V., Jeandin, M., and Malhaire, J.M. (2012, January 21–24). Metallization of a Polymer Using Cold Spray: Application to Aluminum Coating of Polyamide 66. Proceedings of the International Thermal Spray Conference, Houston, TX, USA.10.31399/asm.cp.itsc2012p0265 ↗
67. (2022, December 15). Dielectric Manufacturing ABS Material Properties. Available online: https://dielectricmfg.com/knowledge-base/abs/.
68. Experimental Characterization of the Mechanical Properties of 3D Printed ABS and Polycarbonate Parts10.1007/978-3-319-41600-7_11 ↗
69. Mechanical Behaviour of ABS: An Experimental Study Using FDM and Injection Moulding Techniques10.1016/j.jmapro.2015.11.002 ↗
70. Testing of Materials for Rapid Prototyping Fused Deposition Modelling Technology
71. Gilbert, M. (2017). Aliphatic Polyamides. Brydson’s Plastics Materials, Butterworth-Heinemann. [8th ed.].10.1016/B978-0-323-35824-8.00018-9 ↗
72. Effect of the Ironing Process on ABS Parts Produced by FDM
73. A Model Research for Prototype Warp Deformation in the FDM Process10.1007/s00170-006-0556-9 ↗
74. Layered Manufacturing With Embedded Components: Process Planning Considerations
75. Micromechanics of Amorphous Metal/Polymer Hybrid Structures with 3D Cellular Architectures: Size Effects, Buckling Behavior, and Energy Absorption Capability10.1002/smll.201602514 ↗
76. (2022, December 14). ASTM Standard Test Method for Determining Strength of Adhesively Bonded Rigid Plastic Lap-Shear Joints in Shear by Tension Loading. Available online: https://www.astm.org/d3163-01r14.html.
77. (2013). Standard Test Methods for Tension Testing of Metallic Materials (Standard No. ASTM Standard E8/E8M-13a).
78. (2022, December 15). Markforged Material Datasheet Composites. Available online: https://static.markforged.com/downloads/composites-data-sheet.pdf.
79. (2022, December 15). Fillamentum 3D Printing Guide—Fillamentum Nylon CF15 Carbon. Available online: http://www.fillamentumautomotive.com/wp-content/uploads/2020/10/FI_Printing_Guide_Nylon_CF15_Carbon.pdf.
80. Effect of the Printing Bed Temperature on the Adhesion of Parts Produced by Fused Filament Fabrication10.1080/14658011.2017.1399531 ↗
81. Influence of Adherend Surface Roughness on the Adhesive Bond Strength10.1590/1679-78253066 ↗
82. (2022, December 27). Filmetrics ProfilmOnline—Surface Imaging, Analysis, and Measurement Software for 3D Profilometers and AFMs. Available online: https://www.profilmonline.com/.
83. Bechtel, S., Schweitzer, R., Frey, M., Busch, R., and Herrmann, H.-G. (2022). Material Extrusion of Structural Polymer–Aluminum Joints—Examining Shear Strength, Wetting, Polymer Melt Rheology and Aging. Materials, 15.10.3390/ma15093120 ↗
84. Effect of Surface Treatment on the Shear Strength of Aluminium Adhesive Single-Lap Joints for Automotive Applications10.1016/j.ijadhadh.2015.12.023 ↗
85. Influence of Aluminum Surface Pre-Treatments on the Bonding Mechanisms and Mechanical Performance of Metal-Composite Single-Lap Joints10.1007/s40194-017-0509-y ↗
86. Evaluation of Aluminum to Composite Bonded Lap Joints10.1177/09540083221111443 ↗
87. Musiari, F., and Moroni, F. (2021). Experimental Study of the Influence of the Surface Preparation on the Fatigue Behavior of Polyamide Single Lap Joints. Materials, 14.10.3390/ma14041008 ↗
88. Aluminum Sheet Surface Roughness Correlation with Adhesion in Polymer Metal Hybrid Overmolding10.1016/j.cirp.2011.03.073 ↗
89. Adhesive Bond Strength Enhancing between Carbon Fiber Reinforced Polymer and Aluminum Substrates with Different Surface Morphologies Created by Three Sulfuric Acid Solutions10.1016/j.compositesa.2021.106427 ↗