CN109416306A - 用于测试微孔发泡热塑性复合材料焊接部的剪切性能的夹具 - Google Patents

用于测试微孔发泡热塑性复合材料焊接部的剪切性能的夹具 Download PDF

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CN109416306A
CN109416306A CN201780035941.0A CN201780035941A CN109416306A CN 109416306 A CN109416306 A CN 109416306A CN 201780035941 A CN201780035941 A CN 201780035941A CN 109416306 A CN109416306 A CN 109416306A
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test
substrate
lateral
thermoplastic composite
sample
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马里厄斯·基楚
Y 希门尼斯 亚历克西斯·巴尔扎克
史蒂文·莫里
基思·瓦德
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Magna Decoration Co
Magna Exteriors Inc
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    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
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Abstract

具有用于对经焊接的热塑性复合材料部件中的焊接界面的性能进行测试的搭接剪切测试夹具和使用方法，所述热塑性复合材料部件比如为红外焊接的或电阻植入焊接的或粘合结合的复合材料部件。待被测试的试样由生产就绪部件提供并具有典型几何形状。测试夹具包括具有至少两个侧向支承块状件的至少两个对准的块状件，其中，所述至少两个侧向支承块状件能够对包括有两个经焊接的基板的试样以可操作的方式保持。测试在压缩模式下以预定的十字头速度执行，直到由万能试验机所产生的最大载荷使两个热塑性基板之间的焊接界面在剪切模式下失效为止。

Description

用于测试微孔发泡热塑性复合材料焊接部的剪切性能的夹具
相关申请的交叉引用
本申请要求于2016年6月10日提交的美国临时申请No.62/348,264的权益。上述申请的公开内容通过参引并入本文中。
技术领域
本发明涉及一种用以对用于车辆的红外焊接的热塑性复合材料部件或电阻植入焊接的或粘合结合的复合材料部件的焊接界面进行测试的测试夹具，并且涉及关于该测试夹具的方法。
背景技术
用以接合热塑性复合材料的典型技术可以包括：粘合结合、机械紧固以及焊接。常用焊接工艺可以包括：超声焊接、激光焊接、红外焊接、高频焊接以及电阻植入焊接，仅提及这几种。因为焊接工艺受到比如时间、温度和压力之类的参数的控制，对于每一种应用特别是对于生产不能以单个步骤制造出的大型复杂的结构件而言需要对焊接参数进行细致优化。
工艺的选择受到待接合的材料、接合部的构型、所需的接合部的强度、工艺成本和速度、以及生产量的影响。焊接工艺依赖于在焊接界面处熔融的聚合物，这允许聚合物链的相互扩散横穿两个被粘物发生，其中，在冷却时形成焊接部。
通常，有必要的是，在材料形成和处理过程期间对焊接界面的强度进行测试。测试需要可靠的可重复的且有成本效益的方法来确定应力集中、分层、部件的几何形状和厚度对焊接部的机械性能方面的影响。
存在多种方式来确定焊接部在不失效的情况下可以承受的最大载荷。在剪切、张紧或压缩的模式下使用的破坏性测试方法可以与单搭接接合试样和双搭接接合试样结合使用，或者借助于块剪切测试夹具而使用。然而，这些方法通常需要具有特定几何形状和机械性能的测试试样，这可能在实际的生产就绪部件中并不总是可获得的。
因此，对全尺寸部件的质量和性能进行验证具有挑战，特别是在焊接微孔发泡热塑性复合材料成为新趋势的汽车行业中具有挑战。
例如，传统的车辆提升式门的几何形状是复杂的。这实际上限制了可以被切割出以用于对焊接部的性能进行测试的试样的形状、厚度和大小。通过大量试验，已经发现在单搭接接合试样中使用低表面能量粘合剂需要较长的固化周期(该固化周期在室温下通常为72小时)并且通常在产生焊接部失效之前失效、特别是在热塑性基板中的一个热塑性基板具有非常低的机械性能的情况下在焊接部失效之前失效。这通常是微孔发泡热塑性复合材料的情况。在块剪切夹具与发泡热塑性材料结合使用时已经发现了试样过度翘曲和弯曲，这导致基板的过早失效，而不是焊接界面的过早失效。
一种通常已知的测试夹具是被设计成将使两种材料脱开结合所需的最大载荷隔离的块剪切测试夹具，其中，所述两种材料具有比界面的模量更大的模量。该测试夹具通常适用于下述红外焊接(IR-welded)的聚合物基板：所述红外焊接的聚合物基板具有至少60MPa的抗拉强度并且具有被结合在具有12.7mm厚度的3×3"块状件的中央处的大约25.4×25.4mm的块状件的试样几何形状。这种类型的几何形状在生产就绪部件中通常是不可获得的，从而使抽样和测试过程具有挑战。通常需要更小的测试试样。这种类型的测试夹具的主要限制在于，这种类型的测试夹具与低抗拉强度(＜60MPa)的材料不兼容，该低抗拉强度的材料比如为微孔发泡热塑性复合材料，因为测试试样在测试期间往往大幅翘曲和弯曲。
因此，需要的是具有简单、快速、准确且可重复的测试夹具来对红外焊接的热塑性复合材料部件中的焊接界面的性能进行测试。
发明内容
本发明总体上涉及一种简单、快速、准确且可重复的测试夹具，该测试夹具用以对在红外(IR)焊接的热塑性复合材料部件中的焊接界面的性能进行测试，所述红外(IR)焊接的热塑性复合材料部件比如为用于车辆的提升式门或其他汽车用组件。特别是当热塑性复合材料中的一种热塑性复合材料是微孔发泡的且具有低抗拉强度(例如，＜25MPa)时涉及所述测试夹具。
试样可以从生产就绪部件中切割出并且具有例如20×25mm且厚度达3.0mm的典型几何形状。在低抗拉强度热塑性基板比如微孔发泡热塑性复合材料中的焊接界面可以以这种方式进行测试，从而使测试过程更简单且更快速地完成。
具有预定大小(优选地，60×25×9mm)的至少两个钢制矩形块状件(块状件1和块状件2)在一个端部处以可操作的方式被加工成保持试样(优选地，具有20×25mm且厚度达3mm的试样)。块状件1和块状件2在每侧相对于各个支承块状件对准(优选地，在块状件1与块状件2之间具有0.02mm的间隙)。测试在压缩模式下通常以预定十字头速度(优选地为1mm/min(毫米每分钟))执行，直到由万能试验机所产生的最大载荷使两个热塑性基板之间的焊接界面在剪切模式下失效为止。
本发明允许对使具有低抗拉强度的两个微孔发泡热塑性复合材料基板之间的焊接界面在剪切模式下脱开结合所需的最大载荷进行测量。另外，不需要低能量表面粘合剂。此外，因为不需要进行粘合剂固化(adhesive curing)，因此测试周期通常更快。此外，仅需要小的试样，并且小的试样可以从生产就绪部件中切割出并且具有预定厚度(优选地，介于3.0mm与1.0mm之间)。
根据下文中所提供的详细描述，本发明另外的应用领域将变得明显。应当理解的是，该详细描述和具体示例虽然表示本发明的优选实施方式但是意在仅出于说明的目的而非意在限制本发明的范围。
附图说明
根据详细描述和附图，将更充分地理解本发明，在附图中：
图1是根据本发明的一个实施方式的测试夹具的立体图；
图2是根据本发明的一个实施方式的测试夹具的正视图；以及
图3是现有技术的块剪切测试夹具的立体图。
具体实施方式
优选实施方式的以下描述实际上仅是示例性的，而非意在对本发明、本发明的应用、或者本发明的用途进行限制。
总体上参照根据本发明的图1至图2，提供了总体上以附图标记10示出的测试夹具，该测试夹具包括至少第一块状件12和相对的第二块状件14，该第一块状件12和该第二块状件14以可操作的方式联接至基部16。第一块状件12和第二块状件14是侧向支承块状件。第一块状件12和第二块状件14是大致矩形的，不过任何其他合适的形状(例如，在图2中所描绘的第一块状件12a和第二块状件14a)也在本发明的范围内。在优选实施方式中，每个块状件为大约60×25×9毫米(mm)。第一块状件12和第二块状件14是金属的、最优选地是钢的。
还提供了至少第一夹持件18(例如，上部夹持件)和第二夹持件20(例如，该第二夹持件20低于第一夹持件)。第一块状件12和第二块状件14在相应的侧上与第一夹持件18和第二夹持件20以可操作的方式对准，使得第一夹持件18和第二夹持件20布置在介于第一块状件12与第二块状件14之间的空间中，该空间总体上由附图标记22指示。在第一夹持件18与第二夹持件20之间存在预定大小的间隙，该预定大小的间隙通常为大约0.001mm至0.02mm、通常为大约0.015mm、优选地为大约0.018mm、最优选地为0.02mm的最大间隙。
在第一夹持件18中设置有第一通道26并且在第二夹持件20中设置有第二通道28，以用于对具有至少两个半部(第一基板30a和第二基板30b)的测试样本或“试样”(比如在图2中总体上以附图标记30所示出的)或“板件”进行保持，其中，所述至少两个半部在预定位置处具有焊接界面。在不脱离本发明的范围的情况下，设想到其他形状和构型。在样本30被装载在通道26、28中的情况下，随后在需要执行搭接剪切测试时通过万能试验机的装置32将载荷施加(例如，向下施加，如由箭头“F”所指示的)在装载点上、优选地向下施加在更高的第一夹持件18的顶部上。该测试在压缩模式下通常以1mm/min的十字头速度执行，直到由万能试验机所产生的最大载荷使两个热塑性基板之间的焊接界面在剪切模式下失效为止。
搭接剪切测试夹具和方法的特征在于发泡基板的焊接强度具有低抗拉强度(＜25MPa)。焊接线的失效是可重复的。此外，测试夹具具有紧凑型设计，这允许针对生产就绪部件进行测试。
根据本发明的实施方式，用于搭接剪切测试的方法包括提供如上面所描述的测试夹具10。预定的样本30被制备。通过非限制性示例，样本30为发泡热塑性烯烃(TPO)红外焊接的板件。然后，样本30以可操作的方式被装载至测试夹具10，并且执行测试。通过示例的方式，搭接剪切测试方法是DPPD20160419p(参照ASTM D4501，25.4×20mm，1mm/min)。
一般而言，测试在压缩模式下通常以1mm/min的十字头速度执行，直到由万能试验机所产生的最大载荷使两个热塑性基板之间的焊接界面在剪切模式下失效为止。
本发明提供了一种简单、快速、准确且可重复的测试夹具，该测试夹具用以对在IR焊接的热塑性复合材料提升式门中的焊接界面的性能进行测试。特别是当热塑性复合材料中的一种热塑性复合材料是微孔发泡的热塑性复合材料且具有低抗拉强度(比如＜25MPa)时提供了所述测试夹具。此外，试样30可以从生产就绪部件中切割出并具有比如20×25mm且厚度达3.0mm的典型几何形状。在低抗拉强度热塑性基板比如微孔发泡热塑性复合材料中的焊接界面可以以这种方式进行测试，从而使测试过程更简单且更快速地完成。
本发明允许对使具有低抗拉强度的两个微孔发泡热塑性复合材料基板之间的焊接界面在剪切模式下脱开结合所需的最大载荷进行测量。此外，不需要低能量表面粘合剂。此外，因为不需要进行粘合剂固化，因此测试周期通常更快。此外，仅需要小的试样，并且小的试样可以从生产就绪部件中切割出并具有介于3.0mm与1.0mm之间的厚度。
在不脱离本发明的范围的情况下，设想到除了IR焊接之外的任何其他接合工艺，比如但不限于RIW(电阻植入焊接)。
图3图示了总体上以附图标记100示出的现有技术的块剪切测试夹具，该现有技术的块剪切测试夹具具有下述28×28mm样本：该28×28mm样本利用测试方法DPPD20160419(ASTM D4501，28×28mm，1mm/min)被测试，直到发生过早失效为止。然而，该失效是关于基板的，而不是关于焊接界面的。
本发明的描述本质上仅是示例性的，并且因此，不脱离本发明的本质的变型意在属于本发明的范围内。这种变型不应被视为脱离本发明的精神和范围。

Claims (20)

1.一种用于对热塑性复合材料基板之间的焊接界面进行测量的测试夹具，所述测试夹具包括：
第一侧向支承块状件，所述第一侧向支承块状件以可操作的方式联接至第一夹持件，所述第一夹持件具有第一通道，所述第一通道用于以可操作的方式保持测试样本的第一基板；
第二侧向支承块状件，所述第二侧向支承块状件与所述第一侧向支承块状件平行并且所述第二侧向支承块状件以可操作的方式联接至第二夹持件，所述第二夹持件定位成低于所述第一夹持件并且具有第二通道，所述第二通道能够操作成用于保持测试样本的第二基板，所述第二基板被焊接至所述第一基板；
压缩装置，所述压缩装置对所述第一侧向支承块状件的装载点施加载荷。
2.根据权利要求1所述的测试夹具，其中，所述基板被红外焊接、或者被电阻植入焊接、或者被粘合结合。
3.根据权利要求1所述的测试夹具，其中，所述热塑性复合材料基板中的至少一个热塑性复合材料基板是微孔发泡的并且具有小于25MPa的低抗拉强度。
4.根据权利要求1所述的测试夹具，其中，所述测试夹具是用以确定所述测试样本的焊接强度的搭接剪切测试夹具，其中，所述测试样本从生产就绪部件中获得。
5.一种对复合材料基板之间的焊接界面进行测试的方法，所述方法包括：
提供具有两个相对的块状件的紧凑型的测试夹具，其中，所述两个相对的块状件以可操作的方式联接至两个夹持件；
提供具有被焊接到一起的两个基板的部件试样；
将经焊接的部件试样装载到所述测试夹具中；
对所述两个夹持件中的一个夹持件施加载荷；
对使所述两个基板之间的所述焊接界面脱开结合所需的最大载荷进行测量。
6.根据权利要求5所述的方法，其中，所述焊接是红外焊接或电阻植入焊接或粘合结合。
7.根据权利要求5所述的方法，其中，所述基板中的至少一个基板是微孔发泡热塑性烯烃基板或纤维增强热塑性复合材料。
8.根据权利要求5所述的方法，其中，所述基板中的至少一个基板具有低的抗拉强度。
9.根据权利要求8所述的方法，其中，所述抗拉强度小于25MPa。
10.根据权利要求5所述的方法，其中，所述部件试样为20×25mm且3mm厚。
11.根据权利要求5所述的方法，其中，所述两个夹持件之间的距离最大为0.02mm。
12.根据权利要求5所述的方法，其中，所述两个块状件中的每个块状件的上部部分是60×25mm且9mm厚。
13.根据权利要求5所述的方法，其中，所述测试是在压缩模式下执行的。
14.根据权利要求13所述的方法，其中，所述测试以1mm/min的十字头速度执行，直到所产生的最大载荷使所述两个基板之间的所述焊接界面在剪切模式下失效为止。
15.根据权利要求5所述的方法，其中，所述测试根据DPPD20160419p(参考ASTM D4501，25.4×20mm，1mm/min)来执行。
16.根据权利要求5所述的方法，还包括：将所述部件试样切割成1.0mm至3.0mm厚。
17.根据权利要求5所述的方法，其中，对所述部件样本未使用粘合剂。
18.根据权利要求5所述的方法，其中，对所述部件样本未进行粘合剂固化。
19.一种用于对两个微孔发泡热塑性复合材料基板之间的焊接界面进行测量的紧凑型测试夹具，所述测试夹具包括：
第一侧向支承块状件，所述第一侧向支承块状件以可操作的方式联接至第一夹持件，所述第一夹持件对测试样本的所述两个微孔发泡热塑性复合材料基板中的第一微孔发泡热塑性复合材料基板进行保持，所述第一微孔发泡热塑性复合材料基板在至少一个预定位置中被焊接至所述测试样本的所述两个微孔发泡热塑性复合材料基板中的第二微孔发泡热塑性复合材料基板；
第二侧向支承块状件，所述第二侧向支承块状件与所述第一侧向支承块状件对准并与所述第一侧向支承块状件间隔开，并且所述第二侧向支承块状件以可操作的方式联接至第二夹持件，所述第二夹持件保持所述测试样本的所述第二基板；以及
压缩装置，所述压缩装置能够操作成对所述第一侧向支承块状件或所述第二侧向支承块状件的装载点施加载荷，而所述第一侧向支承块状件或所述第二侧向支承块状件中的另一者不具有由所述压缩装置施加的直接载荷，直到最大载荷使所述两个微孔发泡热塑性复合材料基板之间的所述焊接界面在剪切模式下失效为止。
20.根据权利要求19所述的测试夹具，还包括形成于所述第一夹持件中的第一通道以及形成于所述第二夹持件中的第二通道，其中，所述通道在所述装载点被施加载荷之前对准以保持所述测试样本并且所述通道在所述最大载荷使所述焊接界面在剪切模式下失效时变得未对准。
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KR20190018447A (ko) 2019-02-22
JP2019517676A (ja) 2019-06-24
CA3026986A1 (en) 2017-12-14
EP3469333B1 (en) 2020-09-30

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