| Summary: | The joining of dissimilar materials is becoming increasingly important, especially for structural applications, and in transportation industries to reduce the weight and thus decrease fuel consumption and Co2 emissions. Joining lightweight materials (metals and polymers) is commonly performed using mechanical fastenings, such as screws, bolts, and rivets, or adhesion techniques. However, disadvantages of such mechanical methods are considerable stress concentration around the fastener hole, the potential for corrosion problems, and the possibility of fatigue cracking in metallic materials. Ultrasonic joining (USJ) is particularly suitable where rapid processing and good process reliability are demanded. Quality, strength, and energy saving capabilities also characterise ultrasonic joining. A relatively good body of work exists for polymer-polymer and metal-metal USJ, but little research has been conducted into the joining of dissimilar materials. This is therefore the focus of this thesis. The amorphous thermoplastic polymer (ABS 750SW) and the aluminium alloy (Al6082-T6) are common engineering materials for the manufacturing of hybrid structure and components for engineering applications. These light-weight materials' applications in the transportation industries include both decorative and structural parts, such as internal and external panels, and bumpers. Additionally, metal - polymer laminates are a much more desirable and versatile option, when the replacement of a full metal construction is required. This work presents a comprehensive study of the novel joining of these two materials through USJ and investigates the effect of joining parameters on the joint strength. The joints have been bonded without using any additional materials (fillers).
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