Thermosetting Resin Composite Joining by Friction Stir Welding
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Solution Overview
Problem
Thermoplastic resin composite materials have low initial rigidity and high temperature dependency, while thermosetting resin composite materials cannot be joined through friction stir welding due to their thermosetting nature, and existing joining methods for these materials with metals are costly and complex.
Innovation Solution
A resin composition combining a monomer with ethylenically unsaturated bonds, an unsaturated polyester or vinyl ester resin, a radical polymerization initiator, and a fiber reinforcing material, which can be joined with metals using friction stir welding, allowing for the creation of a thermosetting resin composite material with high mechanical strength and low temperature dependency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermosetting resin composite materials are used, then mechanical strength and dimensional accuracy are improved, but the materials cannot be joined through friction stir welding due to their thermosetting nature
Solution Approach 1:
The invention changes the chemical composition parameters of the thermosetting resin by incorporating a specific unsaturated polyester resin with controlled molecular weight and functional group content. This parameter modification enables the cured thermosetting resin to achieve both high mechanical strength and sufficient chain mobility at welding temperatures, making friction stir welding feasible while maintaining excellent mechanical properties.
Solution Approach 2:
The invention creates a composite resin system combining thermosetting resin (unsaturated polyester or vinyl ester) with specific additives and modifiers. This composite formulation allows the material to exhibit both the strength characteristics of thermosetting resins and the weldability typically associated with thermoplastics, enabling friction stir welding of cured thermosetting composite materials.
2Strength
If physical joining or chemical joining methods are used to join SMC, BMC and metals, then joining is achieved, but the number of steps increases and manufacturing cost increases
Solution Approach 1:
The invention merges the joining operation with the existing friction stir welding process used for thermoplastics. By modifying the thermosetting resin composition to enable weldability, the separate joining step is eliminated and integrated into the standard friction stir welding workflow, reducing process complexity and manufacturing cost while maintaining strong joints between SMC, BMC, and metal components.
3Ease of manufacture
If thermoplastic resin composite materials are used, then friction stir welding is enabled, but initial rigidity is low and temperature dependency of mechanical strength is great
Solution Approach 1:
The invention changes the fundamental chemical nature of the resin from thermoplastic to a modified thermosetting system. The unsaturated polyester or vinyl ester resin, when cured, provides rigid crosslinked networks that ensure high initial rigidity and temperature stability. Simultaneously, the specific composition allows sufficient chain mobility at welding temperatures to enable friction stir welding, thus overcoming the limitations of conventional thermoplastics.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables efficient joining of thermosetting resin composite materials with metals by friction stir welding, resulting in a product with high mechanical strength and reduced temperature dependency, improving manufacturing efficiency and cost-effectiveness.
Implementation Method 1
a resin composition including a monomer (A) having an ethylenically unsaturated bond, an unsaturated polyester resin or a vinyl ester resin (B), a radical polymerization initiator (C), and a fiber reinforcing material (D)
Implementation Method 2
pressing, while rotating, a cylindrical tool against at least a part of the aforementioned member, and joining the aforementioned cured product and the member by means of frictional heat due to friction and agitation
Data Source
AI summary
A friction stir welding method using a resin composition including: a monomer (A) having an ethylenically unsaturated bond; a thermosetting resin (B); a radical polymerization initiator (C); and a fiber reinforcing material (D), wherein the thermosetting resin (B) is an unsaturated polyester resin or a vinyl ester resin.