University of Kerbala

College of Engineering
Mechanical Eng. Dept.

Studying Aluminum Alloy Joining with Nylon 6,6 Using

Hot Pressing Process

By : Hussein Maher Saad Haider

Under Supervised by:-

Prof. Dr. Moner Hameed Tolephih

Prof. Dr. Adnan Naama Abood
INTRODUCTION
Joining has been considered as a key enabling technology to original and
sustainable manufacturing. Metal/polymer composite laminates have been
used in a wide variety of applications in electronics, automotive, defense and
aerospace industries because they includes the overall mechanical properties
of the laminated structure based on the properties of the constituents and due
to
decrease fuel consumption and contaminant emissions, a weight reduction
that coupled with an advanced safety performance of the candidate materials
must be achieved. For this specific reason, there have been continuous
efforts to make automotive body parts from aluminum alloy sheets in place
of steel sheets where polymer is used as basic parts of safety and reduces
fuel consumption and polluting emissions
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 Joining by means of induction heating is an appropriate joining technology for the bonding of
Peter Mitscgang metal/TP-FRPC as it is utilized by a rapid heat generation. The main results of the work were: Pre-
1- 2009 Germany treatment methods, corundum blasting, and acidic pickling awarded the metallic joining partners higher
et al
bonding strength, the bonding strength is roughly twice to (14) MPa for AlMg3-CF/PA66-joints
] used laser-induced fusion technology to bond metal pins with plastics. Titanium alloy Ti-Al6-V4 and
austenitic stainless steel were heated by laser irradiation and then pressed into polycarbonate and
2- Holtkamp et al 2009 Germany
polymethyl methacrylate. The results showed that shear-strength tests of the joint increases with
increasing structure density
Two different plastics were utilized, for the induction joining experiments. With the laser transmission
Andreas joining showed that the shear strength of the joint was elevated by increasing the structure density. The
3- 2011 Germany mechanical interlock of the joint established and high shear strengths up to (24) MPa can be achieved.
Roesner et al
Without any pre-treatment, a joining process cannot be expected at hand for all plastic materials.
investigated the employing of laser to join thermoplastics PA6.6 with steel thermally without the help
of any additives. The chief process parameters were examined with several joining strategies Laser -
4- Bergmann et al 2012 Germany transparent and non-nontransparent. For each of the process changes, subscriber fails within PA6.6 had
been achieved. It had also been shown that there is no association between the standard surface
roughness and shear strength of joining
the clinching process to join aluminum and Carbon Fiber Reinforced Polymer (CFRP) thin sheets, .
The increase in the punch diameter involved a higher material flow, leading to joints with larger
Francesco
5- 2016 Italy undercuts, while, on the other hand, it also produced more damage to the CFRP. The nominal shear
Lambiase et al strength of the joints was calculated as the ratio between the shear strength to the reference joint area
and ranged from (5.8) MPa to (12.9) MPa.

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 • Studying the effect of hot press parameters (pressure, temperature
THE
OBJECTIVE and time) on the shear tensile strength for the dissimilar joints of
1 Al/ polymer.

THE • Assessing the influence of bonding parameters on polymer

OBJECTIVE structures and its properties.
2

THE Investigating the impact of hot press parameters on the failed

OBJECTIVE
3 models of the bonding joints

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Experimental Work

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 Materials
In this study, two main types of materials were used:
1- aluminum alloy AA6061-T6
2- polyamide (nylon 6,6). In addition, two Nylon composites were employed
(1% carbon Nano tube, nylon with 30% carbon fiber).
The chemical and mechanical properties of aluminum alloy are presented in
tables.

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 Bonding Specimen
Aluminum alloy AA 6061-T6 sample for bonding was prepared from a plate with a
thickness of (12) mm, while nylon sample 6,6 was prepared from (10) mm thickness plate.
The dimensions of the samples were (15 * 15) mm as shown in figure.

PA6,6

Al

Fig.11. Schematic of polyamide and Aluminum 7

assembly
 Specimen Vacuum Storage
Desiccator
Pressure gage

In order to protect the surface of

the aluminum after anodizing, a
Compressor
storage device was set up to store
the samples as shown in figure.

Hot Press Equipment Presser

The equipment used is intended to join

aluminum samples with the polyimide nylon6,6 Die fixture

by applying pressure and temperature during a

Heater plate
certain period. The hot press rig is shown in
figure. The highest pressure can be used was
approximately (10) bars.

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The fixture consisted of two parts; the first one is the alloy of aluminum with dimensions (200
* 100 * 100) mm. The groove was made in the middle with a distance of (16 * 8) mm that
allowing the samples of bonding to be placed inside it. The second one is the graphite that
used to prevent the samples movement when they have been pressed.

Aluminum

Graphite

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SINGLE SHEAR LAP TEST
A single shear test has been done by a
compression testing machine of type (WP 300)
with a (20) KN maximum capacities. This
machine is available in material Lab / technical
Institute of Baghdad. The sample has
dimensions of (15) mm wide and (15) mm
length. In order to achieve the shear test of the
sample, a steel fixture was manufactured.
Figure (4.10) represents the schematic of the
shear fixture. The Single shear lap was
evaluated by equation (1).
τ=P/A ………..(1)
Where( τ) is the shear strength (MPa), ( P) is
the applied force (N) and (A) is the area of the
sample (mm2). 10
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Anodizing cell
Anodizing cell setup has been created as
shown in Figure .It is consists of four
parts;
1-The power supply which converts AC
into DC, with voltages ranging (0–60)
volts and a current range (0-15) Amp.
2- Digital multi-meter was used with
three levels.
3- anode.
4- cathode

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Results

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Aluminum to Nylon 6,6 Bonding at 200 C

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Aluminum to Nylon 6,6 Bonding At (220) °C

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 Aluminum to Carbon-Fiber Nylon6,6 Composite Bonding at 220 C

a b c

Al 30%CF/PA66

d e Bonding area
Bonding area
a

19 (c) 1 minute, (d) 1.25 minute, (e)

Failure at 220°C , 2bar in (a) 0.5 minute,(b) 0.75 minute,
2 minute
 a b
a b

Al 30%CF/PA66

Al 30%CF/PA66

c d

c d

e
e

Figure (5-8): Interfacial shear failure at 220°C, 4bar in (a) 0.25minute

,(b) 0.5minute, (c) 0.75minute, (d) 1minute, (e) 1.25 minute

Figure (5-7): Failure at 220°C, 3bar in (a) 0.25minute

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,(b) 0.5minute, (c) 0.75minute, (d) 1minute, (e) 1.25 minute
Aluminum / CNT's Reinforcing Nylon 6,6 Bonding at 200

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a b

Al 1%CNT/PA66

c d

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Figure (5-11); Interfacial shear failure at 220°C , 4 bar (a) 0.25minute
,(b) 0.5minute, (c) 0.75minute, (d) 1minute, (e) 1.25 minute
The Effect Of Bonding By Hot Press On The Molecular Structure Of Nylon

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Average anodizing thickness

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Aluminum surface morphology (a) Two dimension (b) Three dimension

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SEM examination indicates bonding area with a depth of (8) μm
approximately

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The microstructure of the aluminum alloy was not exposed to transformation
whereas the bonding temperature was less than recrystallization temperature
(450 °C of AA6061

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EDS line map provides good information about bonding interface

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 EDS map line of Nylon 6,6 and Al joint (a) Carbon, (b) Oxygen, (c)
b
Aluminum

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DSC & TGA chart of PA6,6 (a)before joint (b) after joint

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DSC & TGA chart of 1% CNT's reinforcing nylon 6,6 (a)before joint (b) after
joint

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DSC & TGA chart of %30 Carbon fiber reinforcing nylon 6,6(a)before joint
(b) after joint

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