A review of metal-to-plastic joinery in automotive manufacturing

Research Article
Open access

A review of metal-to-plastic joinery in automotive manufacturing

Jiajian Fu 1* , Jiahao Lu 2 , Qi Liu 3 , Jiahao Hu 4
  • 1 Chongqing University    
  • 2 York School    
  • 3 Guizhou University    
  • 4 Vision Academy    
  • *corresponding author jiajianfu@cqu.edu.cn
Published on 25 September 2023 | https://doi.org/10.54254/2755-2721/12/20230337
ACE Vol.12
ISSN (Print): 2755-273X
ISSN (Online): 2755-2721
ISBN (Print): 978-1-83558-013-4
ISBN (Online): 978-1-83558-014-1

Abstract

Reducing weight and improving energy efficiency are key design goals in the automotive industry，In order to reduce the weight of the car body, engineers often use plastics in the parts of the car that require less strength. However, due to the difference in material properties, when using plastics to connect steel frames, there are disadvantages such as small interface area, large number of interfaces, and poor reliability of plastics, which may have a great impact on the safety of the car. Therefore, these plastic parts Joinery to the steel frame of the car needs careful consideration. Various methods, such as welding, bolt and nut connection, riveting, and crimping, were considered to connect plastic and metal in automobiles. This article first introduces the specific implementation of the joinery method between plastic and metal, and investigates their process difficulty, interface strength, vibration resistance and the least negligible cost. Discusses where these processes are suitable for use in the car, where they are currently used, and explores potential future developments.

Keywords:

welding, crimping, rivet, bolts and nuts.

Fu,J.;Lu,J.;Liu,Q.;Hu,J. (2023). A review of metal-to-plastic joinery in automotive manufacturing. Applied and Computational Engineering,12,184-198.
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References

[1]. S. Katayama and Y. Kawahito, “Laser direct joining of metal and plastic,” Scr. Mater., vol. 59, no. 12, pp. 1247–1250, Dec. 2008, doi: 10.1016/j.scriptamat.2008.08.026.

[2]. K.-W. Jung, Y. Kawahito, M. Takahashi, and S. Katayama, “Laser direct joining of carbon fiber reinforced plastic to aluminum alloy,” J. Laser Appl., vol. 25, no. 3, p. 032003, May 2013, doi: 10.2351/1.4794297.

[3]. K. W. Jung, Y. Kawahito, M. Takahashi, and S. Katayama, “Laser direct joining of carbon fiber reinforced plastic to zinc-coated steel,” Mater. Des., vol. 47, pp. 179–188, May 2013, doi: 10.1016/j.matdes.2012.12.015.

[4]. A. Fortunato, G. Cuccolini, A. Ascari, L. Orazi, G. Campana, and G. Tani, “Hybrid metal-plastic joining by means of laser,” Int. J. Mater. Form., vol. 3, no. S1, pp. 1131–1134, Apr. 2010, doi: 10.1007/s12289-010-0971-1.

[5]. Y. Huang, X. Gao, B. Ma, and Y. Zhang, “Interface Formation and Bonding Mechanisms of Laser Welding of PMMA Plastic and 304 Austenitic Stainless Steel,” Metals, vol. 11, no. 9, p. 1495, Sep. 2021, doi: 10.3390/met11091495.

[6]. M. Graudenz and M. Baur, “Applications of laser welding in the automotive industry,” in Handbook of Laser Welding Technologies, Elsevier, 2013, pp. 555–574. doi: 10.1533/9780857098771.4.555.

[7]. J. Tsujino et al., “New methods of ultrasonic welding of metal and plastic materials,” Ultrasonics, vol. 34, no. 2–5, pp. 177–185, Jun. 1996, doi: 10.1016/0041-624X(96)81780-X.

[8]. F. Balle, G. Wagner, and D. Eifler, “Ultrasonic spot welding of aluminum sheet/carbon fiber reinforced polymer - joints,” Mater. Werkst., vol. 38, no. 11, pp. 934–938, Nov. 2007, doi: 10.1002/mawe.200700212.

[9]. F. Balle and D. Eifler, “Statistical test planning for ultrasonic welding of dissimilar materials using the example of aluminum-carbon fiber reinforced polymers (CFRP) joints,” Mater. Werkst., vol. 43, no. 4, pp. 286–292, Apr. 2012, doi: 10.1002/mawe.201200943.

[10]. F. Balle, G. Wagner, and D. Eifler, “Ultrasonic Metal Welding of Aluminium Sheets to Carbon Fibre Reinforced Thermoplastic Composites,” Adv. Eng. Mater., vol. 11, no. 1–2, pp. 35–39, Jan. 2009, doi: 10.1002/adem.200800271.

[11]. S.-H. Tang, C.-W. Cheng, R.-Y. Yeh, and R.-Q. Hsu, “Direct joining of 3D-printed thermoplastic parts to SLM-fabricated metal cellular structures by ultrasonic welding,” Int. J. Adv. Manuf. Technol., vol. 99, no. 1–4, pp. 729–736, Oct. 2018, doi: 10.1007/s00170-018-2409-8.

[12]. F. Yusof, Y. Miyashita, N. Seo, Y. Mutoh, and R. Moshwan, “Utilising friction spot joining for dissimilar joint between aluminium alloy (A5052) and polyethylene terephthalate,” Sci. Technol. Weld. Join., vol. 17, no. 7, pp. 544–549, Oct. 2012, doi: 10.1179/136217112x13408696326530.

[13]. F. C. Liu, J. Liao, and K. Nakata, “Joining of metal to plastic using friction lap welding,” Mater. Des. 1980-2015, vol. 54, pp. 236–244, Feb. 2014, doi: 10.1016/j.matdes.2013.08.056.

[14]. S. Genc, R. W. Messler, and G. A. Gabriele, “A hierarchical classification scheme to define and order the design space for integral snap-fit assembly,” Res. Eng. Des., vol. 10, no. 2, pp. 94–106, Jun. 1998, doi: 10.1007/BF01616690.

[15]. S. Genc, R. W. Messler, P. R. Bonenberger, and G. A. Gabriele, “Enumerating Possible Design Options for Integral Attachment Using a Hierarchical Classification Scheme,” J. Mech. Des., vol. 119, no. 2, pp. 178–184, Jun. 1997, doi: 10.1115/1.2826233.

[16]. S. Genc, R. W. Messler, and G. A. Gabriele, “A Method for Attachment Design Concept Development in Integral Snap-fit Assemblies,” J. Mech. Des., vol. 122, no. 3, pp. 257–264, Sep. 2000, doi: 10.1115/1.1287926.

[17]. L. Dong, “Compressive responses of snap-fit Ti-6Al-4V octet-truss lattices in structure’s stiffest direction,” 2021.

[18]. R. Xu, Y. He, X. Li, M. Lu, and Y. Chen, “Snap-fit mechanical metamaterials,” Appl. Mater. Today, vol. 30, p. 101714, Feb. 2023, doi: 10.1016/j.apmt.2022.101714.

[19]. Y. Qi, G. Richter, E. Suadiye, M. Kalina, and E. Rabkin, “Plastic Forming of Metals at the Nanoscale: Interdiffusion-Induced Bending of Bimetallic Nanowhiskers,” ACS Nano, 2020.

[20]. S. Shen, B. B. Kanbur, Y. Zhou, and F. Duan, “Thermal and mechanical analysis for conformal cooling channel in plastic injection molding,” Mater. Today Proc., vol. 28, pp. 396–401, 2020, doi: 10.1016/j.matpr.2019.10.020.

[21]. P. Limaye, G. Ramu, S. Pamulapati, and G. K. Ananthasuresh, “A compliant mechanism kit with flexible beams and connectors along with analysis and optimal synthesis procedures,” Mech. Mach. Theory, vol. 49, pp. 21–39, Mar. 2012, doi: 10.1016/j.mechmachtheory.2011.07.008.

[22]. “High-Stiffness, Lock-and-Key Heat-Reversible Locator-Snap Systems for the Design for Disassembly,” J. Mech. Des.

[23]. P. A. Tres, Designing Plastic Parts for Assembly, 7th ed. München: Carl Hanser Verlag GmbH & Co. KG, 2014. doi: 10.3139/9781569905562.

[24]. S. H. Cheraghi, “Effect of variations in the riveting process on the quality of riveted joints,” Int. J. Adv. Manuf. Technol., vol. 39, no. 11–12, pp. 1144–1155, Dec. 2008, doi: 10.1007/s00170-007-1291-6.

[25]. B. Uhe, C.-M. Kuball, M. Merklein, and G. Meschut, “Strength of self-piercing riveted Joints with conventional Rivets and Rivets made of High Nitrogen Steel,” ESAFORM 2021, Apr. 2021, doi: 10.25518/esaform21.1911.

[26]. C. Zhang, R. Gou, M. Yu, Y. Zhang, Y. Qiao, and S. Fang, “Mechanical and fatigue properties of self-piercing riveted joints in high-strength steel and aluminium alloy,” J. Iron Steel Res. Int., vol. 24, no. 2, pp. 214–221, Feb. 2017, doi: 10.1016/S1006-706X(17)30030-4.

[27]. H. Q. Ang, “An Overview of Self-piercing Riveting Process with Focus on Joint Failures, Corrosion Issues and Optimisation Techniques,” Chin. J. Mech. Eng., vol. 34, no. 1, p. 2, Dec. 2021, doi: 10.1186/s10033-020-00526-3.

[28]. L. Calabrese, G. Galtieri, C. Borsellino, G. Di Bella, and E. Proverbio, “Durability of hybrid clinch-bonded steel/aluminum joints in salt spray environment,” Int. J. Adv. Manuf. Technol., vol. 87, no. 9–12, pp. 3137–3147, Dec. 2016, doi: 10.1007/s00170-016-8701-6.

[29]. J. Huang, “A comprehensive review of loosening detection methods for threaded fasteners,” Mech. Syst. Signal Process., 2022.

[30]. M. Zhang, Y. Shen, L. Xiao, and W. Qu, “Application of subharmonic resonance for the detection of bolted joint looseness,” Nonlinear Dyn., vol. 88, no. 3, pp. 1643–1653, May 2017, doi: 10.1007/s11071-017-3336-1.

[31]. “Research on a new-type intelligent locknut.pdf.”

[32]. C. M. Chen, H. L. Chang, and C. Y. Lee, “THE INFLUENCE OF CORROSION ON THE ANTI-LOOSENING PERFORMANCE OF A PRECISION LOCKNUT SUBJECTED TO ROTATION AND PERIODIC IMPACT,” vol. 36, no. 3, 2020.

Cite this article

Fu,J.;Lu,J.;Liu,Q.;Hu,J. (2023). A review of metal-to-plastic joinery in automotive manufacturing. Applied and Computational Engineering,12,184-198.

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The datasets used and/or analyzed during the current study will be available from the authors upon reasonable request.

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Volume title: Proceedings of the 2023 International Conference on Mechatronics and Smart Systems

ISBN：978-1-83558-013-4(Print) / 978-1-83558-014-1(Online)
Editor：Seyed Ghaffar, Alan Wang
Conference website: https://2023.confmss.org/
Conference date: 24 June 2023
Series: Applied and Computational Engineering
Volume number: Vol.12
ISSN：2755-2721(Print) / 2755-273X(Online)

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References

[1]. S. Katayama and Y. Kawahito, “Laser direct joining of metal and plastic,” Scr. Mater., vol. 59, no. 12, pp. 1247–1250, Dec. 2008, doi: 10.1016/j.scriptamat.2008.08.026.

[2]. K.-W. Jung, Y. Kawahito, M. Takahashi, and S. Katayama, “Laser direct joining of carbon fiber reinforced plastic to aluminum alloy,” J. Laser Appl., vol. 25, no. 3, p. 032003, May 2013, doi: 10.2351/1.4794297.

[3]. K. W. Jung, Y. Kawahito, M. Takahashi, and S. Katayama, “Laser direct joining of carbon fiber reinforced plastic to zinc-coated steel,” Mater. Des., vol. 47, pp. 179–188, May 2013, doi: 10.1016/j.matdes.2012.12.015.

[4]. A. Fortunato, G. Cuccolini, A. Ascari, L. Orazi, G. Campana, and G. Tani, “Hybrid metal-plastic joining by means of laser,” Int. J. Mater. Form., vol. 3, no. S1, pp. 1131–1134, Apr. 2010, doi: 10.1007/s12289-010-0971-1.

[5]. Y. Huang, X. Gao, B. Ma, and Y. Zhang, “Interface Formation and Bonding Mechanisms of Laser Welding of PMMA Plastic and 304 Austenitic Stainless Steel,” Metals, vol. 11, no. 9, p. 1495, Sep. 2021, doi: 10.3390/met11091495.

[6]. M. Graudenz and M. Baur, “Applications of laser welding in the automotive industry,” in Handbook of Laser Welding Technologies, Elsevier, 2013, pp. 555–574. doi: 10.1533/9780857098771.4.555.

[7]. J. Tsujino et al., “New methods of ultrasonic welding of metal and plastic materials,” Ultrasonics, vol. 34, no. 2–5, pp. 177–185, Jun. 1996, doi: 10.1016/0041-624X(96)81780-X.

[8]. F. Balle, G. Wagner, and D. Eifler, “Ultrasonic spot welding of aluminum sheet/carbon fiber reinforced polymer - joints,” Mater. Werkst., vol. 38, no. 11, pp. 934–938, Nov. 2007, doi: 10.1002/mawe.200700212.

[9]. F. Balle and D. Eifler, “Statistical test planning for ultrasonic welding of dissimilar materials using the example of aluminum-carbon fiber reinforced polymers (CFRP) joints,” Mater. Werkst., vol. 43, no. 4, pp. 286–292, Apr. 2012, doi: 10.1002/mawe.201200943.

[10]. F. Balle, G. Wagner, and D. Eifler, “Ultrasonic Metal Welding of Aluminium Sheets to Carbon Fibre Reinforced Thermoplastic Composites,” Adv. Eng. Mater., vol. 11, no. 1–2, pp. 35–39, Jan. 2009, doi: 10.1002/adem.200800271.

[11]. S.-H. Tang, C.-W. Cheng, R.-Y. Yeh, and R.-Q. Hsu, “Direct joining of 3D-printed thermoplastic parts to SLM-fabricated metal cellular structures by ultrasonic welding,” Int. J. Adv. Manuf. Technol., vol. 99, no. 1–4, pp. 729–736, Oct. 2018, doi: 10.1007/s00170-018-2409-8.

[12]. F. Yusof, Y. Miyashita, N. Seo, Y. Mutoh, and R. Moshwan, “Utilising friction spot joining for dissimilar joint between aluminium alloy (A5052) and polyethylene terephthalate,” Sci. Technol. Weld. Join., vol. 17, no. 7, pp. 544–549, Oct. 2012, doi: 10.1179/136217112x13408696326530.

[13]. F. C. Liu, J. Liao, and K. Nakata, “Joining of metal to plastic using friction lap welding,” Mater. Des. 1980-2015, vol. 54, pp. 236–244, Feb. 2014, doi: 10.1016/j.matdes.2013.08.056.

[14]. S. Genc, R. W. Messler, and G. A. Gabriele, “A hierarchical classification scheme to define and order the design space for integral snap-fit assembly,” Res. Eng. Des., vol. 10, no. 2, pp. 94–106, Jun. 1998, doi: 10.1007/BF01616690.

[15]. S. Genc, R. W. Messler, P. R. Bonenberger, and G. A. Gabriele, “Enumerating Possible Design Options for Integral Attachment Using a Hierarchical Classification Scheme,” J. Mech. Des., vol. 119, no. 2, pp. 178–184, Jun. 1997, doi: 10.1115/1.2826233.

[16]. S. Genc, R. W. Messler, and G. A. Gabriele, “A Method for Attachment Design Concept Development in Integral Snap-fit Assemblies,” J. Mech. Des., vol. 122, no. 3, pp. 257–264, Sep. 2000, doi: 10.1115/1.1287926.

[17]. L. Dong, “Compressive responses of snap-fit Ti-6Al-4V octet-truss lattices in structure’s stiffest direction,” 2021.

[18]. R. Xu, Y. He, X. Li, M. Lu, and Y. Chen, “Snap-fit mechanical metamaterials,” Appl. Mater. Today, vol. 30, p. 101714, Feb. 2023, doi: 10.1016/j.apmt.2022.101714.

[19]. Y. Qi, G. Richter, E. Suadiye, M. Kalina, and E. Rabkin, “Plastic Forming of Metals at the Nanoscale: Interdiffusion-Induced Bending of Bimetallic Nanowhiskers,” ACS Nano, 2020.

[20]. S. Shen, B. B. Kanbur, Y. Zhou, and F. Duan, “Thermal and mechanical analysis for conformal cooling channel in plastic injection molding,” Mater. Today Proc., vol. 28, pp. 396–401, 2020, doi: 10.1016/j.matpr.2019.10.020.

[21]. P. Limaye, G. Ramu, S. Pamulapati, and G. K. Ananthasuresh, “A compliant mechanism kit with flexible beams and connectors along with analysis and optimal synthesis procedures,” Mech. Mach. Theory, vol. 49, pp. 21–39, Mar. 2012, doi: 10.1016/j.mechmachtheory.2011.07.008.

[22]. “High-Stiffness, Lock-and-Key Heat-Reversible Locator-Snap Systems for the Design for Disassembly,” J. Mech. Des.

[23]. P. A. Tres, Designing Plastic Parts for Assembly, 7th ed. München: Carl Hanser Verlag GmbH & Co. KG, 2014. doi: 10.3139/9781569905562.

[24]. S. H. Cheraghi, “Effect of variations in the riveting process on the quality of riveted joints,” Int. J. Adv. Manuf. Technol., vol. 39, no. 11–12, pp. 1144–1155, Dec. 2008, doi: 10.1007/s00170-007-1291-6.

[25]. B. Uhe, C.-M. Kuball, M. Merklein, and G. Meschut, “Strength of self-piercing riveted Joints with conventional Rivets and Rivets made of High Nitrogen Steel,” ESAFORM 2021, Apr. 2021, doi: 10.25518/esaform21.1911.

[26]. C. Zhang, R. Gou, M. Yu, Y. Zhang, Y. Qiao, and S. Fang, “Mechanical and fatigue properties of self-piercing riveted joints in high-strength steel and aluminium alloy,” J. Iron Steel Res. Int., vol. 24, no. 2, pp. 214–221, Feb. 2017, doi: 10.1016/S1006-706X(17)30030-4.

[27]. H. Q. Ang, “An Overview of Self-piercing Riveting Process with Focus on Joint Failures, Corrosion Issues and Optimisation Techniques,” Chin. J. Mech. Eng., vol. 34, no. 1, p. 2, Dec. 2021, doi: 10.1186/s10033-020-00526-3.

[28]. L. Calabrese, G. Galtieri, C. Borsellino, G. Di Bella, and E. Proverbio, “Durability of hybrid clinch-bonded steel/aluminum joints in salt spray environment,” Int. J. Adv. Manuf. Technol., vol. 87, no. 9–12, pp. 3137–3147, Dec. 2016, doi: 10.1007/s00170-016-8701-6.

[29]. J. Huang, “A comprehensive review of loosening detection methods for threaded fasteners,” Mech. Syst. Signal Process., 2022.

[30]. M. Zhang, Y. Shen, L. Xiao, and W. Qu, “Application of subharmonic resonance for the detection of bolted joint looseness,” Nonlinear Dyn., vol. 88, no. 3, pp. 1643–1653, May 2017, doi: 10.1007/s11071-017-3336-1.

[31]. “Research on a new-type intelligent locknut.pdf.”

[32]. C. M. Chen, H. L. Chang, and C. Y. Lee, “THE INFLUENCE OF CORROSION ON THE ANTI-LOOSENING PERFORMANCE OF A PRECISION LOCKNUT SUBJECTED TO ROTATION AND PERIODIC IMPACT,” vol. 36, no. 3, 2020.

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