Influences of manufacturing process parameters on interfacial strength in an additive manufactured ABS-resin/Al-alloy dissimilar joint

Abstract

In order to develop novel direct manufacturing of ABS resin on Al alloy surface by the 3D printing technique with high interfacial strength, the influences of the temperature and the roughness of the Al-alloy substrate, and the cooling rate after manufacturing on the bonding strength of an additive manufactured ABS-resin/Al-alloy dissimilar joint were investigated. The experimental results reveal that the mechanical interlock mechanism is a primary factor for the adhesion between ABS resin and the Al alloy. Besides, there was optimum surface roughness to improve the interlock effect of the ABS-resin/Al-alloy joints; the high bonding strength was able to be achieved under the condition of the relatively fine roughness of the substrate surface. The surface temperature of the substrate was also an essential factor in getting high bonding strength. The interfacial strength increased with increasing the surface temperature of the substrate because the ABS-resin was able to easily penetrate the subtle depressions of the substrate surface due to the improved resin fluidity. However, the interfacial strength decreased due to high thermal residual stress in the case of a much higher condition of the surface temperature of the substrate. From the experimental results, the optimum process condition to achieve about 10MPa adhesion strength was presented.

Keywords

• additive manufacturing
• shear bonding strength
• surface temperature
• surface roughness
• mechanical interlock effect