Joining of polymer to metal using material extrusion additive manufacturing

Abstract

This study investigates the joining of metal to polymer by material extrusion additive manufacturing. Direct joining by layered extrusion was used to fabricate hybrid single lap joints of Acrylonitrile Butadiene Styrene (ABS) and Aluminum alloy 5052. The in uence of the printing speed, bed temperature and nozzle Z-offset on the lap shear strength was studied experimentally. The interface between the two materials was also observed under scanning electron microscope and the chemical state of the polymer after printing was analyzed using differential scanning calorimetry (DSC), Raman spectroscopy and X-ray Photoelectron Spectroscopy (XPS). The results revealed that elevated bed temperature and pressure application through lowering the Z-offset promoted better polymer lling of the metal surface structure and improved the joint strength by mechanical interlocking. Also, long exposure time to the heated build plate corresponding to low printing speeds lowered the mechanical performance of the polymer bulk due to thermal degradation. Mechanical interlocking was the main joining mechanism, but under high bed temperatures where the carbonyl group had formed due to degradation, a (C-O-Al) chemical bond was detected.

Investigating the Feasibility and Performance of Hybrid Overmolded UHMWPE 3D-Printed PEEK Structural Composites for Orthopedic Implant Applications: A Pilot Study

“…Ding et al [ 29 ] assessed the effect of strut angle (30°, 45°, and 60°) in a truss lattice design, as well as the effects of TPMS lattice (diamond, gyroid, and neovirus) design and porosity (60%, 76%, and 84%) on the interlocking strength between material-jetted UV-curable acrylate and polydimethylsiloxane (PDMS). Zou et al [ 30 ] explored the lap shear strength of overmolded UHMWPE titanium (Ti6Al4V) (produced by electron beam-melted (EBM)) specimens with different porous interfaces (non-structured (dense), diamond, and honeycomb) and Alhmoudi et al [ 31 ] evaluated the interfacial adhesion between acrylonitrile butadiene styrene (ABS) directly extruded onto and an aluminum alloy. Despite the aforementioned studies, there is a lack of literature detailing the ideal porous topologies and surface features to maximize bonding strength between contrasting medical-grade polymer–polymer structures.…”