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Lightweight Metal/Polymer/Metal Sandwich Composites for Automotive Applications

机译：汽车应用的轻质金属/聚合物/金属夹芯复合材料

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摘要

Sandwich composites are becoming increasingly popular in the automotive sector as they are lightweight and facilitate noise attenuation. However, given that sandwich composites are relatively new in the sector, there are questions as to whether they can effectively replace monolithic metals and damping patches without compromising mechanical performance. Quiet Aluminum RTM, a sandwich composite produced by Material Sciences Corporation (MSC), employs as skins two aluminum alloys that are common in automotive manufacturing: 5754-O and 6061-T4. The current study examines and compares the mechanical properties of Quiet AluminumRTM with the main Fiat Chrysler Automobiles (FCA) requirements for laminates with non-structural loads. The adhesion mechanism between the layers of the sandwich composites received was examined through: T-Peel test, roughness measurements and metallographic cross sectioning technique. The current study then employed tensile tests with different treatments applied to the sandwich materials, a Self-Piercing Riveting (SPR) joining evaluation, and hardness tests on the core section of the aluminum skins. The samples, which presented rolling mill-finish surface roughness Ra range of 0.46--0.56 micro m, met the FCA adhesion requirements with adhesive failure mode even after the paint bake-cycle simulation (20 min at 185 °C) and the hardening treatment applied on the sandwich with AA6061-T4 skin (1 h at 200 °C). The tensile properties, computed simulating stamping process (2% pre-applied strain), the paint-bake cycle and the hardening treatment were comparable to the monolithic ones. Finally, SPR technique, evaluated through lap shear test and macro-graphic measurements, successfully joined Quiet AluminumRTM samples (1.06 mm thickness) with structural High Strength Low Alloy steel (HSLA,1.8 mm thickness and 340 MPa minimum yield strength).
机译：夹层复合材料轻巧且可降低噪音，因此在汽车领域正变得越来越流行。但是，鉴于夹芯复合材料在该领域相对较新，因此存在疑问，即它们是否可以有效替代整体式金属和阻尼贴片而不损害机械性能。由材料科学公司（MSC）生产的三明治复合材料Quiet Aluminium RTM使用两种在汽车制造中常见的铝合金作为表皮：5754-O和6061-T4。当前的研究检查并比较了Quiet AluminiumRTM的机械性能与非结构载荷层压板的主要菲亚特克莱斯勒汽车（FCA）要求。通过以下方法检查所接收的夹心复合材料的各层之间的粘附机理：T-剥离测试，粗糙度测量和金相截面技术。然后，当前的研究采用了对夹层材料进行不同处理的拉伸测试，自穿孔铆接（SPR）连接评估以及对铝皮表层核心部分的硬度测试。样品的轧机加工表面粗糙度Ra范围为0.46--0.56微米，即使在模拟油漆烘烤周期（在185°C下进行20分钟）和硬化处理之后，仍具有FCA粘合要求并具有粘合破坏模式。涂在带有AA6061-T4皮肤的三明治上（在200°C下1 h）。拉伸性能，模拟冲压过程（预先施加2％的应变），烤漆周期和硬化处理与整体式相当。最后，通过搭接剪切测试和宏观测量评估的SPR技术成功地将Quiet AluminiumRTM样品（厚度为1.06毫米）与结构高强度低合金钢（HSLA，厚度为1.8毫米，最小屈服强度为340 MPa）结合在一起。

著录项

  • 作者

    Ferrari, Federico.;

  • 作者单位

    University of Windsor (Canada).;

  • 授予单位 University of Windsor (Canada).;
  • 学科 Mechanical engineering.;Materials science.
  • 学位 M.A.Sc.
  • 年度 2017
  • 页码 125 p.
  • 总页数 125
  • 原文格式 PDF
  • 正文语种 eng
  • 中图分类
  • 关键词

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