Joining of plastic‐metal hybrid components by overmoulding of specially designed form‐closure elements

Wurzbacher, Simon; Gach, Stefan; Reisgen, Uwe; Hopmann, Christian

doi:10.1002/mawe.202000158

Cited by 8 publications

(5 citation statements)

References 18 publications

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“…Wurzbacher et al [ 113 ] investigated the potential of Surfi‐Sculpt structures produced by electron beam surface structuring to join different lightweight metals (stainless steel [DIN 1.4301], aluminum alloy [AlMg 2 ], and magnesium alloy [ME20]) and short‐glass‐fiber reinforced polyamide 6 (PA6‐30GF). The Surfi‐Sculpt process generated one or two rows of 10 form‐fit elements each, with a width of 0.5–0.7 mm and a height 1.7–2.5 mm, which were overmolded with PA6‐30GF.…”

Section: Correlation Between Metal Surface Preparation Methods Proces...mentioning

confidence: 99%

Injection overmolding of polymer‐metal hybrid structures: A review

Vasconcelos

Oliveira

Amancio‐Filho

et al. 2023

Polymer Engineering & Sci

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Polymer‐metal hybrid (PMH) structures, also known as metal‐polymer hybrid (MPH) structures, have received considerable attention from industry and academia due to the societal need for developing strong, lightweight, and durable structures for several applications in strategic areas, such as transportation, household appliances, energy, and biomedical devices. Injection overmolding is an advantageous technique for manufacturing PMH structures as it combines automation, a fast process, cost efficiency, and dimensional accuracy. This review presents a comprehensive discussion of recent advances reported in the literature concerning PMH structures fabricated by direct‐adhesion injection overmolding. Following a general introduction, the fundamentals of the injection overmolding technique are presented. Next, the potential of some metal surface preparation methods to ensure good adhesion, and thus outstanding mechanical performance in injection overmolded PMH structures is discussed. Correlations are then made between metal surface features, processing parameters, and the mechanical strength of injection overmolded polymer‐metal joints. Some applications of injection overmolded PMH structures are explored, and, lastly, the main conclusions and prospects on the use of injection overmolding are presented.

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Section: Correlation Between Metal Surface Preparation Methods Proces...mentioning

confidence: 99%

Injection overmolding of polymer‐metal hybrid structures: A review

Vasconcelos

Oliveira

Amancio‐Filho

et al. 2023

Polymer Engineering & Sci

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“…A small portion of the melt can solidify around the opening of the structure when being pushed out of the heat affected zone. By repeating the ablation process with multiple passes an undercut geometry can be created since more and more generated melt solidifies on the surface near the structure opening and its edges [22,28].…”

Section: Creating Micro-form-fitted Structures For Hybrid Components ...mentioning

confidence: 99%

“…The decrease of the tensile shear strength with increased structure spacing can be explained by the reduction of anchorage points per unit area. During the production of microstructures by laser radiation, too small structural spacing can lead to a heat influence in the adjacent structures [22,34]. Due to the increased structure width of the manufactured microstructures of 200 μm, a further reduction of the structure spacing to further increase the tensile shear strength cannot be investigated.…”

Section: Influence Of the Microstructure Distance On The Tensile Shea...mentioning

confidence: 99%

“…Since adhesives cannot be used directly in the injection mould, adhesion promoter systems are normally used for the assembly of the metal component with the plastic component in the in-mould-assembly [19][20][21]. Due to the lack of adhesion promoter systems for the material combination of amorphous thermoplastics and light metals, the aim of the presented study is to investigate the potential of a process combination of laser structuring by laser ablation of the light metal component and subsequent back-moulding with the amorphous plastic component as a joining technology to create strong, micro-form-fit bonds [22,23].…”

Section: Introductionmentioning

confidence: 99%

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Development of micro‐form‐fitted amorphous thermoplast/light metal hybrid components

Wurzbacher

Mascher

Wagner

et al. 2023

Materialwissenschaft Werkst

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In order to meet the high demands on tolerances and surface qualities, for example in automotive lighting applications, a hybrid part composed of a light metal (aluminium) and an amorphous thermoplastic (polycarbonate) could be an alternative to the established mono‐materials used today. Due to the lack of adhesion promoter systems for joining this specific material combination, a micro‐form‐fitted connection by creating undercut microstructures by laser ablation is used to achieve a full‐surface bond. First investigations are carried out to ensure the filling of these microstructures with different polycarbonate moulding compounds by over moulding in the injection moulding process. Subsequently, the influence of the moulding compound, the structure arrangement and the influence of a pickling treatment on the bond strength are analysed by tensile shear testing.

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“…The successful implementation of metal-plastic hybrid compounds was first realized in the late 1990s by over-molding steel sheets with elastomer modified glass fiber reinforced Polyamide (Durethan BKV 130; PA6-GF30) at the front end of the Audi A6 [4]. Following such classic macro form-fit technologies, many new processes for micro form-fit processes through over-molding have been researched over the last few decades [13]. Several other innovative technologies like laser micro structuring on the metal surface [12,14], the mechanical interlocking effect [15,16], electrochemical treatment of metal inserts [17], fiber laser joining [18,19], and laser transmission joining [20], etc., have also been used to attain metal-plastic joints using a variety of different categories of metals and plastics.…”

Section: Introductionmentioning

confidence: 99%

Joining of Macroscopic 3D Steel Transition Wire Structures to Steel Sheets: Study on the Mechanical, Microstructural, and Phase Characteristics of Brazed and Glued Joints

Palaniyappan

Todt

Trautmann

et al. 2022

Metals

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With an increased demand for the combination of different material classes in lightweight applications like automobiles, aircraft construction, etc., the need for simple and energy-efficient joining technologies to join these different material classes has been extensively researched over the last decades. One such hybrid material combination is the metal–plastic hybrid structure, which offers the combinational characteristics of high strength and stiffness of the metal part along with characteristic elasticity and low density of the plastic part. In this research work, the focus is laid on generating a graded property transition at the interface of metal–plastic joints by brazing a three-dimensional (3D) macroscopic transition wire structure (TWS) strucwire®, over the metal part before being molded with plastic at a later stage using an injection over-molding process. This helps in providing a mechanical interlocking facility and thereby achieving a higher load transfer at the interface of metal–plastic hybrid joints. The graded steel wire structures with different carbon content were brazed onto the galvanized steel sheets using the hotplate brazing technique. In addition to the Zinc layer on the galvanized steel sheets, electroplated Zinc coatings were fabricated on the wire structures to provide better brazing quality. The microstructural, mechanical, and intermetallic phase characteristics of the resulting brazed joints were evaluated using light microscopy, adhesion tests, and scanning electron microscopy, respectively.

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Joining of plastic‐metal hybrid components by overmoulding of specially designed form‐closure elements

Cited by 8 publications

References 18 publications

Injection overmolding of polymer‐metal hybrid structures: A review

Injection overmolding of polymer‐metal hybrid structures: A review

Development of micro‐form‐fitted amorphous thermoplast/light metal hybrid components

Joining of Macroscopic 3D Steel Transition Wire Structures to Steel Sheets: Study on the Mechanical, Microstructural, and Phase Characteristics of Brazed and Glued Joints

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