The Critical Energy Release Rate of Welded Joints Between Fiber-Reinforced Thermoplastics and Metals When Thermal Residual Stress is Considered

Abstract

Thermal effects on welded joints between fiber-reinforced thermoplastics (FRTPs) and metals have been investigated theoretically and experimentally. Because FRTPs use thermoplastics as the matrix resin, they have advantages over fiber-reinforced thermoset plastics (FRPs or FRSPs), including the ability to be welded. When dissimilar materials are welded together, however, thermal stress occurs due to the different thermal expansions of the materials and affects the energy release rate of the joint. Therefore, a method for evaluating the true energy release rate, including the effect of thermal stress, is necessary for strength evaluation tests. Although several theories that compensate for the thermal stress and evaluate the true energy release rate have already been proposed, they require parameters that are difficult to measure. Therefore, it is difficult to apply them in experimental investigations. In this article, a theoretical method with easily measurable parameters is proposed to calculate the energy release rate of welded double cantilever beam (DCB) joints. The effect of the thermal stress on the critical energy release rate is discussed in terms of the experimental results of a welded DCB specimen composed of a FRTP and an aluminum alloy.

Keywords:

• Energy release rate
• Fracture mechanics
• FRTP
• Residual stress
• Thermal analysis
• Welding

ACKNOWLEDGEMENTS

The authors express their sincere appreciation to the project members who have provided valuable information and participated in useful discussions.