Showing papers by "C.J. Van Tyne published in 2022"

Joining of metal–plastic composite layered tubes by hydroformed threaded coupling

Abstract: Metal–plastic composite tubular structures, which combine the high strength and stiffness of metallic tubes with the lightweight and flexible properties of plastic tubes, exhibit considerable potential to provide lightweight structures with improved performance compared to conventional monolithic metallic and plastic tubular parts. However, the lack of well-confirmed technologies for connecting metal–plastic composite tubes that can ensure good structural stability and strength has proven problematic in actual applications. In this study, an innovative mechanical joining process via a hydroformed threaded coupling was proposed to achieve the successful joining of metal–plastic composite tubes. For the threaded connection, composite tubes were internally threaded to act as a sleeve, and a threaded coupling tube was externally threaded to act as a screw. The threaded composite tubes and coupling tube were rotated to achieve a secure and robust connection. One-step hydroforming technology was developed to fabricate the threaded tubes and couplings using a single die set. The structural performance of the coupled tubular parts was quantitatively evaluated under axial compression and lateral three-point bending tests. The results showed that the proposed joining process has strong potential for successful utilization in connecting metal–plastic composite tubes for structural applications.