Today's areas of application for lightweight materials range from consumer goods and sports to high technology applications in transportation like aerospace or automotive. Thermoplastic composites manufactured by compression molding, thermoforming, tape laying, or injection molding will play a major role due to their weldability, their suitability for automated production (robot), and their recyclability. To reach a further step of weight reduction, the use of carbon fiber reinforced polymer composites (CFRPC) is unavoidable. A full substitution of metal is unlikely and new developments will consist of a combination of metal and CFRPC. This paper shows new developments in joining hybrids of metal (steel DC01 and aluminum AlMg3) and CFRPC (organic sheets CF‐PA66 and CF‐PEEK). Induction heating is chosen as appropriate joining technology for the bonding of metal/CFRPC as it is characterized by a rapid heating. An explanation of the process, the equipment, the influence of surface treatments, the characterization of the bonding mechanisms, as well as a first step to automation are presented. Basic experiments on the influence of pretreatments and process parameters show great influence of corundum blasting, acidic pickling and temperature control on the shear tensile strength. Joints shear tensile strength of 14.5 MPa for AlMg3/CF‐PA66 and of 20 MPa for DC01/CF‐PEEK, respectively is measured. The documentation of the process parameters shows a high reproducibility and reliability of the developed equipment and demonstrator parts are successfully manufactured.
Joining metal to carbon fiber reinforced polymer (CFRP) with a thermoplastic matrix is an essential contribution to lightweight construction since it offers new design possibilities: the design of hybrid structures. Hybrid structures can realize the optimized application of specific material qualities by enabling the substitution of single metal parts from metal structures with CFRP parts. An analysis of the aging behaviour of hybrid structures and the influence of different pretreatments on the aging behaviour are an essential step towards industrial application.Some results presented in the literature dealing with the aging behavior of metal/polymer joints include Guermazi et al. who researched the aging behavior of high density polyethylene coatings for pipeline applications with the conclusion that the aging affected is based on the diffusion of water molecules into the coating. [1] For the testing, the samples were immersed for six month in synthetic sea water and for reverence also in distilled water at a temperature of 70°C. The tensile strength, the tribological properties and the absorptions rate of the coating were analyzed. Nakache et al. conducted experiments on the aging of polymer/metal joints for submarine applications in sea water with cathodic protection and came to the conclusion that the delamination of the bond was caused by free radicals which were a product of reduced oxygen present in sea water. [2] The examined material was a polychloroprene with silica filler on a substrate of a copper-aluminum alloy. Both studies deal with complete submersion of the joints during the tests and during application. Therefore these results are only of limited comparability to this study. Other investigations which correlate to this study in a better way are: Hoikkanen et al. who tested the aging behavior of metal and ester based thermoplastic urethane (TPU) hybrid joints and compared different pre-treatments after accelerated aging. [3] The used pre-treatment methods for the substrate were electrolytic polishing with different parameters and etching. For the accelerated aging three different parameters were used: Isothermal aging (500 h at 85°C and ambient atmospheric conditions), isohume aging (500 h at 25°C and 85% relative humidity) and a combination of both (500 h at 85°C and 85% relative humidity). It was concluded that the mechanical properties of the joints are mainly dependent on the level of degradation of the TPU. Rahme et al. investigated the influence of humidity (distilled water) in the joining zone to the strength of the bonding. [4] For pre-treatment an acid was used based on 2% hexaflurotitanic acid in water and varied combinations of the additional components phosphoric acid, Manganese phosphate, Titanium and an organic phase (polyvinyl phenol modified with an amino group). It was discovered that the effects of the humidity are reversible just by drying the joints. De'Nève et al. conducted the aging behavior with torsional adhesive joints of bare and zinc electro-coated steel using a fill...
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