Ultrasonic welding of CF/PA6 composite to 6061Al alloy utilizing an interfacial coating as energy director

This study investigates ultrasonic plastic welding to join the carbon fiber-reinforced thermoplastics and 6061Al alloy in a lap-type joint configuration. An interfacial polymer coating through a fluidized bed on aluminum alloy was considered an energy director, as it was essential for concentrating heat at the interface during welding. The significant ultrasonic process setting (weld pressure: 0.5 MPa, weld time: 600 ms, hold time: 1000 ms) was statistically realized for a maximum lap shear strength of the joint that showed the interlaminar shear (first-layer ply) failure of the composite, while the welding interface morphology revealed interdiffusion of thermoplastics with the load-bearing carbon fibers attached to the composite-coating resin mixtures, whereas the coating interface offered a strong adhesion of polymer on the aluminum surface asperities through mechanical interlocking. An efficient multi-material joint was obtained within 1.6 s in comparison to the adhesive bonding technology that required at least 20 min. Additionally, the interfacial coating serves as an insulator, avoiding galvanic corrosion in joints as well as fretting damage. The encouraging findings of this research provide deeper insight into joining thermoplastic composites to metals by ultrasonic plastic welding without the use of a separate energy director, which simplifies the process of industrialization.