Analysis of Thermally Induced Residual Stress in Resistance Welded PC/CF Composite to Aluminum
Marcin Praski, Piotr Kowalczyk, Karolina Stankiewicz, Radosław Szumowski, Piotr Synaszko, Andrzej Leski
TL;DR
This paper studies residual stresses in resistance welded PC/CF composite to aluminum joints, revealing how thermal mismatch affects durability and bond quality.
Contribution
A novel framework for predicting residual stress in hybrid PC/CF–Al joints using FEM and analytical methods is presented.
Findings
The measured mid-span bow remained constant at 16.5 mm across thermal cycles.
FEM underpredicted bow with a 21% Mean Absolute Percentage Error.
Edge-peaked peel stress and σxx were consistent with shear-lag theory and viscoelastic relaxation effects.
Abstract
Thermoplastic composites are growing in popularity in the aerospace and automotive industries; they enable weldable and recyclable structures. Resistance welded hybrid thermoplastic and metal joints are attractive for rapid assembly, but the thermal mismatch between metals and polymers introduces residual stresses, which can drive edge debonding and compromise durability. This study presents fabricated single-lap PC/CF–Al7075 coupons with measured mid-span bow resulting from welding, evaluated bond quality by step-heating thermography, and an evaluated framework for residual stress prediction using Ansys complemented by a bimetal analytical check. Three thermal cycles were examined with different temperature gradients (200, 220, 240 °C): the measured bow was 16.5 mm and remained constant, whereas analytical calculation increased with ΔT similarly to the FEM prediction. The current FEM…
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Taxonomy
TopicsAdvanced Welding Techniques Analysis · Mechanical Behavior of Composites · Welding Techniques and Residual Stresses