新能源电动汽车异种材料连接技术的挑战、趋势和进展

doi:10.11896/cldb.19020049

Abstract
Figure/Table
References
Related Citation (15)

Download:

Full Text ( PDF ) (2519KB)
Export: BibTeX | EndNote (RIS)

Abstract The emerging trend towards lightweight, high performance and emissions reduction is leading to the increasing use of multi-material hybrid structures in electric vehicles. Advanced high-strength steel (AHSS), lightweight alloy, such as aluminum, titanium and magnesium, as well as plastics and carbon fiber reinforced polymers (CFRP) etc. are being used extensively in the manufacture of body in white, automotive panels and complex structural parts.
Due to different physical and chemical properties of base materials, it becomes a challenging task to join dissimilar materials. For joining of aluminum alloy to CFRP, fusion welding often produces defects such as softening, porosity, hot cracks in the heat affected zone of aluminum alloy. Moreover, it causes the CFRP fibers and matrix to partially burn. Mechanical fastening can also cause inevitable corrosion and other problems. At the same time, battery pack housing, which is composed by multi-materials, has a high requirement for the joining technology. Accordingly, the use of optimized composite materials urgently need the development of innovative joining technology with reliable performance, low cost, and high efficiency in order to provide light-weight body structure for new energy vehicles.
Adhesive is widely used in aluminum alloy/AHSS, aluminum alloy/CFRP, AHSS/CFRP etc., which can achieve sealing, fastening and anti-corrosion effects. As a newly developed mechanical joining technology, self-piercing riveting (SPR) is more suitable for joining aluminium alloy, AHSS and CFRP than fusion welding. There have been mature studies on its joining mechanism and joint strength overseas. Additionally, solid phase welding is especially suitable for joining metal/composite. The novel technology and equipment of refill friction stir spot welding (RFSSW) and ultrasonic spot welding for joining aluminium alloy/CFRP and AHSS/CFRP have been explored and improved in many studies. Laser hybrid welding and cold metal transfer welding (CMT) are mainly used in the joining of aluminium alloy and AHSS in the majority of automotive enterprises. Fasteners are mainly used for the joining of battery pack, while laser welding of particular materials is used for housing sealing.
The paper reviews the advanced and alternative joining methods for CFRP to aluminum/steel, aluminum to steel and battery pack manufactu-ring, ranging from conventional adhesive bonding, weld-bonding and self-piercing riveting to new welding technologies, such as friction stir spot welding, ultrasonic spot welding, laser braze-welding and cold metal transfer welding. The effects of joining parameters on joint properties and fai-lure modes are discussed. The difficulties and research status of fatigue life prediction based on finite element analysis are discussed. These joining technologies have prominent advantages in the joining of hybrid material structure of new energy electric vehicles, but they still face the problems of matrix damage, interface failure, long welding cycle, expensive equipment and industrial automation etc., therefore further research is required to completely exploit these methods in practical applications.

Key words： electric vehicle advanced high strength steel (AHSS) aluminum carbon fiber-reinforced polymers (CFRP) battery pack dissimilar material joining

Published: 30 September 2019

CLC number:

TG424

Fund:This work was financially supported by Beijing University of Technology Seed Fund for International Science and Technology Cooperation (2018-A12) and Beijing International Science and Technology Cooperation Base of Carbon-based Nanomaterials.

About author:: Hong Li is currently an associate professor of Beijing University of Technology. She received her Ph.D. degree in Materials Processing Engineering from University of Science and Technology, Beijing, in 2006. From 2006 to 2008, she worked as a postdoctor in Beijing University of Technology. From 2012 to 2013, she carried out visiting scholar research funded by CSC in Dortmund University of Technology. In 2013, she was appointed as vice-chair of Sub-Commission C-XVII-C (Soldering) of International Institute of Welding (IIW). Her main research fields include brazing, joining of dissimilar materials and micro-nano scale joining. She has published more than 70 research papers and obtained 14 granted China natio-nal invention patents.
Xusheng Liu received his B.E. degree in Materials Science and Engineering from Shijiazhuang Railway University in 2017. He is currently pursuing his master degree in College of Materials Science and Engineering, Beijing University of Technology under the supervision of A./Prof. Hong Li. His research has focused on friction stir spot welding of carbon fiber reinforced polymer with aluminum alloys.

	Service
	E-mail this article
	Add to my bookshelf
	Add to citation manager
	E-mail Alert
	RSS
	Articles by authors
	LI Hong
	LIU Xusheng
	ZHANG Yisheng
	JACEK Senkara
	LI Guangying
	MA Mingtu

Cite this article:

LI Hong,LIU Xusheng,ZHANG Yisheng, et al. Current Research and Challenges in Innovative Technology of Joining DissimilarMaterials for Electric Vehicles[J]. Materials Reports, 2019, 33(23): 3853-3861.

URL:

http://www.mater-rep.com/EN/10.11896/cldb.19020049 OR http://www.mater-rep.com/EN/Y2019/V33/I23/3853

Yang G F, Zhou Q F, Hou M Y, et al. International Petroleum Econo-mics,2017,25(4),59(in Chinese).杨国丰,周庆凡,侯明扬,等.国际石油经济,2017,25(4),59.2 Yu Z B. Commercial Vehicles,2015,6(6),23(in Chinese). 于占波.商用汽车,2015,6(6),23.3 Lang Y. Automobile Applied Technology,2018,33(5),104(in Chinese).郎勇.汽车实用技术,2018,33(5),104.4 Huetter J. Repairer Driven News,2017,4,5.5 http://www.gg-ev.com/asdisp2-65b095fb-19122-.html.6 Li C W. Aeronautical Manufacturing Technology,2011,20(19),88(in Chinese).李春威.航空制造技术,2011,20(19),88.7 Zhang K, Yang Z, Li Y, et al. International Journal of Adhesion & Adhesives,2013,46,7.8 Abed G H. Effects of temperature on the adhesive bonding in steel beams reinforced with CFRP composites. Ph.D. Thesis, University of Southampton,UK,2012.9 Pramanik A, Dong Y. Composites Part A,2017,101,1.10 Li H, Li Z X. Automobile Technology,2008(2),1(in Chinese).李红,栗卓新.汽车技术,2008(2),1.11 Kweon J H, Jung J W, Kim T H, et al. Composite Structures,2006,75,192 .12 Kahlmeyer M, Böhm S. Welding in the World,2016,60,767.13 Reitz V, Meinhard D, Ruck S, et al. Composites Part A,2017,96,18.14 Wu Y, Kong H J, Ding X M, et al. Fiber Reinforced Plastics/Composites,2018(4),56(in Chinese).吴瑶,孔海娟,丁小马.玻璃钢/复合材料,2018(4),56.15 Wang H, Hao H, Yan K, et al. Journal of Materials Processing Technology,2018,257,213.16 Yang X L. The mechanical properties of adhesive bonded joints for lightweight automotives. Ph.D. Thesis, Dalian University of Technology, China,2014(in Chinese).杨晓莉.汽车轻量化异种材料胶接接头力学性能研究.博士学位论文,大连理工大学,2014.17 Duan Y X, Zhang K F, Wang Z Q, et al. Journal of Mechanical Engineering,2012,48(4),44(in Chinese).段元欣,张开富,王中强,等.机械工程学报,2012,48(4),44.18 Chen L H. Auto Engineer,2014,44(14),58(in Chinese).陈丽华.汽车工程师,2014,44(14),58.19 Wu X D, Wang M, Kong L, et al. Electric Welding Machine,2016,46(4),31(in Chinese).吴小丹,王敏,孔谅,等.电焊机,2016,46(4),31.20 Franco G D, Fratini L, Pasta A, et al. International Journal of Adhesion and Adhesives,2013,43(1),24.21 庄蔚敏,刘西洋,敖文宏,等.中国专利,CN105479771A,2015.22 Landgrebe D, Niegsch R. Key Engineering Materials,2015,651-653(1),1493.23 Mandel M, Krüger L. Materialwissenschaft Und Werkstofftechnik,2015,45(12),1123.24 Franco G D, Fratini L, Pasta A, et al. Journal of Materials: Design and Applications,2012,226(3).230.25 Rao H M, Kang J, Huff G, et al. International Journal of Fatigue,2018,113,11.26 Zhang J, Yang S L. Journal of Composite Materials,2015,49(12),1493.27 Zhang J, He X C, Ding W Y, et al. Ordnance Material Science and Engineering,2018,41(3),48(in Chinese).张杰,何晓聪,丁文有,等.兵器材料科学与工程,2018,41(3),48.28 Lambiase F, Ko D C. Materials & Design,2016,107,341.29 Jäckel M, Grimm T, Niegsch R, et al. Proceedings,2018,2(384),1.30 Amancio-Filho S T, Bueno C, Dos Santos J F, et al. Materials Science & Engineering: A,2011,528,3841.31 Goushegir S M, Santos J F D, Amancio-Filho S T, et al. Materials & Design,2014,54(2),196.32 Esteves J V, Goushegir S M, Santos J F D, et al. Materials & Design,2015,66(4),437.33 André N M, Goushegir S M, Santos J F D, et al. Composites Part B,2016,94,197.34 Ogawa Y, Xiong Y, Akebono H, et al. Science & Technology of Welding & Joining,2017,23(4),1.35 Ogawa Y, Akebono H, Tanaka K, et al. Science & Technology of Welding & Joining,2018,10,1.36 Huang Y X, Meng X, Xie Y, et al. Composites Part A Applied Science & Manufacturing,2018,112,328.37 Peng J. Study on friction stir welding process of ABS and aluminum alloy. Ph.D. Thesis, Lanzhou University of Technology, China,2016(in Chinese).彭军.ABS与铝合金搅拌摩擦焊工艺研究.博士学位论文,兰州理工大学,2016.38 Wen C J, Li Y L, Zhao C, et al. Transactions of the China Welding Institution,2015,36(9),39(in Chinese).温昌金,李玉龙,赵诚,等.焊接学报,2015,36(9),39.39 Palardy G, Villegas I F. In:Proceedings of the American Society for Composites-31st Technical Conference, ASC 2016. Virginia,2016,pp.1884. 40 Zhao D W, Ren D X, Zhao K M, et al. Journal of Mechanical Enginee-ring,2017,53(24),118(in Chinese).赵德望,任大鑫,赵坤民,等.机械工程学报,2017,53(24),118.41 Balle F, Wagner G, Eifler D, et al. In: Proceeding of the 12th International Conference on Aluminium Alloys (ICAA12). Japan,2010,pp.591.42 Wagner G, Balle F, Eifler D, et al. Advanced Engineering Materials,2013,15(9),792.43 Lionetto F, Morillas M N, Pappadà S, et al. Composites Part A Applied Science & Manufacturing,2018,104,32.44 Lionetto F, Mele C, Leo P, et al. Composites Part B: Engineering,2018,144,134.45 Zhang W H. Study on resistance spot welding of dissimilar materials of aluminum alloy and high strength steel. Ph.D. Thesis, Jilin University, China,2011(in Chinese).张伟华.铝合金/高强钢异种金属电阻点焊研究.博士学位论文,吉林大学,2011.46 Zhang M J, Chen G Y, Zhang Y, et al. Materials & Design,2013,45(6),24.47 Yi Y L, Chen J P. Hot Working Technology,2016(15),49(in Chinese).衣玉兰,陈建萍.热加工工艺,2016(15),49.48 Zhang L Y, Dong W P, Liu Y F, et al. Light Industry Machinery,2017,35(1),45(in Chinese). 张立艳,董万鹏,刘雅芳,等. 轻工机械,2017,35(1),45.49 Li L Q, Xia H B, Tan C W, et al. Journal of Materials Processing Technology,2018,252,573.50 Piccini J M, Svoboda H G. Procedia Materials Science,2015,9,504.51 Chen K, Liu X, Ni J, et al. Journal of Manufacturing Science & Engineering,2017,139(8),1.52 Piccini J M, Svoboda H G. Journal of Manufacturing Processes,2017,26,142.53 Lyu X C, Li M, Li X, et al. International Journal of Advanced Manufacturing Technology,2018,96,2875.54 Lan S, Liu X, Ni J, et al. International Journal of Advanced Manufactu-ring Technology,2016,82(9-12),2183.55 Ramachandran K K, Murugan N, Kumar S S, et al. Chemistry,2015,6(22),4071.56 Zhang Z K, Yu Y, Zhang J F, et al. Metals-Open Access Metallurgy Journal,2017,7(9),338.57 Ibrahim I, Uematsu Y, Kakiuchi T, et al. Science & Technology of Wel-ding & Joining,2015,20(8),670.58 Cao R, Sun J H, Chen J H, et al. Welding Journal,2014,583(3),622.59 Silvayeh Z, Vallant R, Sommitsch C, et al. Metallurgical and Materials Transactions A,2017,48(11),5376.60 Jin X, Li Y, Lou M, et al. Chinese Journal of Automotive Engineering,2011,1(3),185.61 He X, Gu F, Ball A, et al. International Journal of Advanced Manufacturing Technology,2012,58(5-8),643.62 Lou M, Li Y B, Li Y T, et al. Journal of Manufacturing Science & Engineering,2013,135(1),1.63 Lou M, Li Y B, Wang Y, et al. Journal of Materials Processing Technology,2014,214(10),2119.64 Huang L, Shi Y, Guo H, et al. International Journal of Fatigue,2016,88,96.65 Chung C S, Kim H K. Fatigue & Fracture of Engineering Materials & Structures,2016,39(9),1105.66 Kang Y U, Xing B, He X C, et al. Ordnance Material Science & Engineering,2018,41,1004.67 Savoy Mark A, Armaki H G. Great Designs in Steel,2018,2,145.68 Dallner C, Zeiher V. Kunststoffe-International,2011,3,66.69 Schmerler R, Gebken T, Kalka S, et al. Lightweight Design Worldwide,2017,10(5),26.70 Baumeister J, Weise J, Hirtz E, et al. Procedia Materials Science,2015,45(12),1099.71 Zhao H L, Chu J P, Wang X T, et al. Auto Time,2017(24),64(in Chinese).赵河林,楚金甫,王许涛,等.时代汽车,2017(24),64.72 Cheng P. Welding Productivity,2017,10,22.73 Bai J Y. The research on laser welding process of battery bus bar for new energy vehicle. Ph.D. Thesis, Changchun University of Science and Technology, China,2017(in Chinese).白健宇.新能源汽车电池母排激光焊接工艺研究.博士学位论文,长春理工大学,2017.74 Choi C H, Hahm Y H, Kang H M, et al. U. S. patent: US20120103714A1,2012.75 Liu S L, Xia S L, Zhao J Z, et al. Automobile Applied Technology,2016(11),10(in Chinese).刘舒龙,夏顺礼,赵久志,等.汽车实用技术,2016(11),10.76 Mao Z W, Li W, Liu Y Q, et al. Chinese Journal of Power Sources,2016,40(5),977(in Chinese).毛占稳,李炜,刘宇强,等.电源技术,2016,40(5),977.77 卢胜圩.中国专利,CN106217903A,2016.