International Scientific Journals
of Scientific Technical Union of Mechanical Engineering "Industry 4.0"

The paper discusses the possibilities of joining thin-walled metals and composites reinforced with bidirectional carbon/glass fibres. The experimental part of the paper contains metallographic sections and results of load-bearing capacity testing of pilot metalcomposite joints with thermoplastic matrix and glass and carbon fiber reinforcement, formed by thermal drilling technology. As a result, a sequential joining method is proposed which can achieve the optimum joint geometry with a hem to keep the joint from opening under tensile stress.

The article deals with determinatin the optimum parameters for thermal drilling of selected Al, Mg and steel alloys to be subsequently used for joining with thermoplastic matrix composites reinforced with bidirectional continuous fibers. The optimum thermal drilling parameters will be considered to be those which produce a bushing of sufficient length and thickness to penetrate the composite material to a thickness of 1.5 mm.

The paper focuses on the evaluation of the quality of joints of thin-walled dissimilar overlapped materials, formed by thermal drilling without a screw. The shaped interference fit joint is formed by simultaneously forming both overlapped materials, preheated by the friction of a flowdrill tool, and forming a pair of embedded concentric bushings. The joints were made on a CNC milling centre, at constant speed, with tool feed being the only variable. Three tool movement strategies – three movement schemes – were tested. By evaluating the quality of the joints using metallographic sections, the optimum tool movement strategy was selected.