Mitigation of distortion of Al/steel part under simulated paint baking condition: Experiment and numerical model studies

Huang, Hui; Wang, Yanli; Lim, Yong Chae; Boettcher, Eric; Feng, Zhili

doi:10.1016/j.jmapro.2024.11.003

Mitigation of distortion of Al/steel part under simulated paint baking condition: Experiment and numerical model studies

Journal Article · Tue Nov 12 00:00:00 EST 2024 · Journal of Manufacturing Processes

DOI:https://doi.org/10.1016/j.jmapro.2024.11.003· OSTI ID:2477515

Huang, Hui ^[1]; Wang, Yanli ^[2]; Lim, Yong Chae ^[2]; Boettcher, Eric ^[3]; Feng, Zhili ^[2]

Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States); Shanghai Jiao Tong Univ. (China)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Honda R&D Americas, LLC, Raymound, OH (United States)

Multi-material joining of lightweight structures is essential to reduce vehicle weight for more energy savings and less greenhouse gas emission. However, mismatch of thermal expansion coefficient for dissimilar materials during the paint baking process can induce part distortion and joint failure for adhesive bonding. Here, in the present work, a thermomechanical model based on contact mechanics and large deformation theory was developed for dissimilar high-strength Al alloy and steel components to study the distortion mechanism and influential factors of the residual gap. The established model was used to optimize joint conditions, such as pitch distance and part geometry. When a weld pitch is shorter than 100 mm, the maximum gap between Al and steel part can be greatly reduced to 0.1 mm, and the local stress and plastic strain around the joint during the oven heating and cooling cycle are also substantially reduced compared with the long pitch case (900 mm). The numerical modeling results revealed that a comparable bending stiffness ratio between the steel and Al cross sections is critical to the minimization of gap and distortion under paint baking condition. Digital image correlation technique was used to measure the overall part distortion and local strain distribution that were used to validate the model prediction. Weld bonding (adhesive bonding with friction bit joining) process was successfully employed to join Al to steel component without gap opening in adhesive after the paint baking and cooling.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Vehicle Technologies Office (VTO)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 2477515

Journal Information:: Journal of Manufacturing Processes, Journal Name: Journal of Manufacturing Processes Journal Issue: 26 Vol. 132; ISSN 1526-6125

Publisher:: Society of Manufacturing Engineers; ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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36 MATERIALS SCIENCE
42 ENGINEERING
Adhesive bonding
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measurement
numerical model
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