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LaserjoiningcarbonfiberreinforcedplastictostainlesssteelIndustrialLaserSolutions

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Laserjoiningcarbonfiberreinforced
plastictostainlesssteel
07/15/2014

Methodeliminatesenvironmentaldrawbacks

SEIJIKATAYAMAandYOUSUKEKAWAHITO

AgroupattheJoiningandWeldingResearchInstitute(JWRI)ofOsakaUniversityin
Japan,underthedirectionofProfessorSeijiKatayama,hassucceededindirectlaser
joiningofcarbonfiberreinforcedplastic(CFRP)toAISI304metal.ILSaskedProfessor
Katayamatopresentdetailsofthisstudy.

Carbonfiberreinforcedplastic(CFRP)iscurrentlyattractinggreatattentionduetothe
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material'shighstrengthtoweightratio,excellentcorrosionresistance,andoutstanding
fatigueproperties,whichhasledtoitsuseforaircraft,automobiles,andotherproducts.
TheautomobileindustryisespeciallyinterestedinthethermoplastictypeCFRP,where
itisexpectedtoshortenproductiontime.
JoiningofplasticorCFRPtometalisusuallyconductedbyusingadhesivebonds
(glues)ormechanicaltoolssuchasboltsandrivets.However,thesejoiningprocesses
haveseveraldrawbacks,suchasenvironmentalrestrictionofvolatileorganic
compound(VOC)emission,alongbondingtime,andanincreaseinweightduetobolts
orrivets.Therefore,laserassistedmetalandplastic(LAMP)directjoininghasbeen
developedbyProfessorS.Katayama'sgrouptorapidlyproducestrongjointsbetween
commerciallyavailablemetalssuchassteel,stainlesssteel,andaluminumalloy,and
engineeringthermoplasticssuchaspolyamide(PA),polyethyleneterephthalate(PET),
andpolycarbonate(PC)usingacontinuouswave(CW)Nd:YAGlaser,diodelaser,
fiberlaser,ordisklaser.
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LAMPjoiningwasappliedtoproduceastrongjointbetweenaCFRPsheetandType
304stainlesssteelplatebyproducingapartiallypenetratedweldinthemetalwitha
CWdisklaser.FIGURE1showsthelaserlapjointbetweenapolyacrylonitrile(PAN)
type,PAmatrixCFRPsheetwithlongercarbonfibersof3mmthicknessand20mm
widthandaType304stainlesssteelplateof3mmthicknessand30mmwidthbefore
andafterthetensilesheartest.Thecrosssectionalphoto(INSET)demonstratesa
laserweldbeadmadeinstainlesssteelbyashallowkeyhole.Moreover,themelted
areaiswidelyformedinsidetheCFRPsheetnearthejointinterface.Itisobservedin
FIGURE1BthatblackCFRPremainsadheredtothebottomsurfaceoftheType304
stainlesssteelplate.Inparticular,adheringCFRPischieflyrecognizedonthesteel
plateunderthelaserweldbead.Partofthesteelisalsofoundontheinterfacesurface
ofCFRPsheet.Thesefactssuggestthattheformationofastrongbondedjointis
feasible.

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FIGURE1.SurfaceappearanceofCFRPandType304stainlesssteelafteraLAMP
joiningexperiment(a),acrosssectionofweldfusionzoneandjoiningarea(b),and
fracturedsurfaceappearanceoftheLAMPjointaftertensilesheartest(c).
FIGURE2showsthetensilesheartestresultsofjointsmadeunderdifferentdisklaser
irradiationconditions.Theresultsshowthatthemaximumtensileshearload(strength)
ofthejointwasabout4800N(for20mmwideCFRP)undertheproperconditionsof
2kWpowerand5mm/stravelingspeed,whichwashigherthanahalfofthetensile
shearloadofthebaseCFRPsheet.Thetensileshearloadofthejointof30mmwide
and3mmthickPAplasticsheettoType304steelplatewasabout3400Natthe
maximum.Itisjudgedthatthemaximumloadof20mmwideCFRPsheettoType304
steelplateisbyfarhigherthanthatof30mmwidePAplasticsheettosteelplate.
Therefore,thehighestloadcanbeachievedbytheproductionofthelapjointbetween
PANtype,PAmatrixCFRPwithlongercarbonfibersandType304steel.

FIGURE2.TensilesheartestresultsofseverallaserlapjointsbetweenCFRPsheet
andType304plate,showingdifferentvaluesdependinguponlaserpowerandtraveling
speed.
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FIGURE3exhibitsscanningelectronmicroscopy(SEM)photosofthetightlybonded
jointneartheinterfacebetweenCFRPandType304stainlesssteel.Manybubblesof
submillimetersizeareirregularlyformedinthematrixplasticaroundcarbonfibersby
heatconductionfromthehightemperatureofamoltenpoolduringlaserwelding.Itwas
confirmedthatthegeometricalcharacteristicsofthebubblesinsidetheCFRP
dependedonthelaminatedshapeoftheplasticandcarbonfibers,aswellasthelevel
ofconductedheatandthelengthofcarbonfibers.Itisunderstoodthatbubblesare
moreeasilyformedinCFRPthananormalplastic.Althoughthebubblesareformed
justneartheinterfaceinthecaseofanormalplasticinthecaseofCFRP,thebubbles
arewidelyspreadintheplasticmatrixduetotheinstabilitybetweenfibersurfacesand
thematrixandhigherheatconductivityofcarbonfibers.

FIGURE3.SEMphotosatlowermagnificationsnearthejointinterface(a)andat
highermagnifications(b)oftheblueboxedregionin(a).
FIGURE4isatransmissionelectronmicroscopy(TEM)photonearthejointinterface
andshowsTEMEDSanalysisresultsofrespectivetypicalpointsinPAmatrix,oxide
filmonthestainlesssteel,andsteelmatrix.ItisobservedthatCFRPisbondedonthe
atomicormolecularscaleona10nmthickchromiumiron(CrFe)oxidelayerofType
304steel.Thissuggestsahighpossibilityofchemicalbondingandphysical(Vander
Waals)bonding.Therefore,CFRPandType304stainlesssteelcouldbebondedso
tightlyastoproduceastrongjoint.

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FIGURE4.TEMphotonearthejointinterfaceofalaserlapjointbetweenCFRPsheet
toType304plate(left),andTEMEDSanalysisresultsofrespectivetypicalpoints(a),
(b),and(c)(right).
Moreover,thegascompositionsinsidethebubbleswereanalyzedwithaQmass
spectrometerbymeasuringthevacuumlevelandthemassspectraofgasesemitted
duringthedrillingofaholemeasuringabout2mmindiameterfromtheCFRPsheetto
thesteelplateunderahighvacuumof7106Pa.Asaresult,thegascomponents
insidethebubblesconsistofN2inair,H2,andthehydrocarbonseriesasthepyrolysis
gasesfromthePAmatrixofCFRP.Themeltedplasticwasmovedbythehighpressure
causedbythegenerationandrapidexpansionofbubblesafterthepyrolysis,andthen
flowedinanygroovesorgrainboundariesofthemetalsurface.Asthebonding
mechanismsdeducedfromalltheexperimentsareindicatedinFIGURE5,CFRP
compositesweredirectlyjoinedtothesteelbychemicallyorphysicallybondingthe
meltedplasticandtheoxidefilmcoveringthestainlesssteelinadditiontothe
mechanicalanchoreffectduetoplasticflowedinthepits,grooves,orgrainboundaries.

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FIGURE5.LaserdirectjoiningmechanismsoflapjointbetweenCFRPandmetal.
ThislaserjoiningtechniqueofCFRPtometalisexpectedtobeutilizedbyindustry.
ThismethodwasalsoappliedtojoinCFRPtoaluminumalloyorzinc(Zn)coatedsteel,
anditwasconfirmedthatstrongjointscouldbeproduced.

Acknowledgement
TheauthorsappreciateandacknowledgeDr.K.W.Jung,whoperformedjoining
experimentsundertheNEDO(NewEnergyandIndustrialTechnologyDevelopment
Organization)Project.

SEIJIKATAYAMA(mkatayama@jwri.osakau.ac.jp)isdirector/professorand
YOUSUKEKAWAHITOisanassociateprofessor,bothattheJoiningandWelding
ResearchInstitute(JWRI)atOsakaUniversity,Osaka,Japan.

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