Design and Experimental Concept for Dissimilar Ultrasonic Welding Joints for Aluminum Alloy to Glass-Fiber-Reinforced Polymer Tubes

 

Michael de Leon1*, Mark Angelo Diaz2, Richard Pascua3, and Gellieca Dullas4

*email: deleonmichael@staff.anu.ac.kr

 

Abstract

This conceptual study explores ultrasonic welding (UW) for creating joints between aluminum alloy A5052-H32 and glass-fiber-reinforced polymer (GFRP) cylindrical tubes, capitalizing on the method's advantages, such as low energy requirements, minimal heat-affected zones, and direct energy transfer to the weld interface. The research, conducted by the group with extensive expertise in solid-state joining and material deformation under extreme conditions, responds to the growing demand for reliable, fast, and cost-effective joining technologies. The proposed hybrid-UW technique introduces gradient functions at the joint interface, aiming to enhance the performance of Al/GFRP dissimilar joints. The manuscript not only outlines the technical approach and experimental methods employed but also highlights the distinctive aspects of the proposed technology. In addition to detailing the materials used and the design considerations for the ultrasonic welder's horn and anvil, the study provides a glimpse into the practical implementation of the proposed hybrid- UW technique. The limited joints made during the experimental phase serve as a proof-of-concept for the feasibility and potential effectiveness of the approach.

Keywords: Ultrasonic welding, Dissimilar joints, Aluminum alloy, Glass-fiber-reinforced polymers, Hybrid ultrasonic welding, Joint interface, Lightweight materials, Joining technology.

 

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