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Joining Carbon Fiber and Aluminum with Ultrasonic Additive Manufacturing

Gingerich, Mark Bryant
http://orcid.org/0000-0001-9620-9965
http://rave.ohiolink.edu/etdc/view?acc_num=osu1461161262

Abstract Details

2016, Master of Science, Ohio State University, Mechanical Engineering.
Due to increasing emphasis on lightweighting to increase fuel efficiency, integration of carbon fiber reinforced polymers (CFRP) with metal structures is necessary. Current adhesive and mechanical fastening methods used for joining CFRP to metals are not ideal due to poor mechanical properties and incompatibility with current manufacturing infrastructure. Consequently, new joining techniques are needed for increasing the use of CFRP. In this research project, a method of creating joints between CFRP and 6061-H18 aluminum was developed by using ultrasonic additive manufacturing (UAM). The UAM process was used to embed dry carbon fiber tows within an aluminum matrix, creating a mechanical joint between the two materials. The joints were then integrated with additional CF fabrics and epoxy, forming a fully integrated CF-Al structure. This technique was used to create CF-Al joints for tensile, cross tensile, and three-point-bend testing. Mechanical test results showed that the UAM constructed joints had superior strength when compared to adhesive single lap joints. Throughout the UAM joint manufacturing process, experimental observations paired with FEA were used to help solve issues with foil tearing, which is a common problem experienced when materials are embedded with UAM.
Marcelo Dapino (Advisor)
Anthony Luscher (Committee Member)
174 p.
Aerospace Engineering; Automotive Engineering; Automotive Materials; Engineering; Experiments; Materials Science; Polymers
UAM; ultrasonic additive manufacturing; CFRP to metal joining; automotive joining; aluminum; carbon fiber; ultrasonic consolidation; hybrid transition structures; adhesive benchmarking; carbon fiber integration

Recommended Citations

Citations

  • Gingerich, M. B. (2016). Joining Carbon Fiber and Aluminum with Ultrasonic Additive Manufacturing [Master's thesis, Ohio State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=osu1461161262

    APA Style (7th edition)

  • Gingerich, Mark. Joining Carbon Fiber and Aluminum with Ultrasonic Additive Manufacturing. 2016. Ohio State University, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=osu1461161262.

    MLA Style (8th edition)

  • Gingerich, Mark. "Joining Carbon Fiber and Aluminum with Ultrasonic Additive Manufacturing." Master's thesis, Ohio State University, 2016. http://rave.ohiolink.edu/etdc/view?acc_num=osu1461161262

    Chicago Manual of Style (17th edition)

osu1461161262
78
© 2016, all rights reserved.
This open access ETD is published by The Ohio State University and OhioLINK.