Thermal direct joining of metal to fiber reinforced thermoplastic components

Abstract

In the field of lightweight construction, load-capable mixing compounds with the material specific advantages of metal and thermoplastics become increasingly significant. For this efficient process, chains including adapted pretreatment and joining processes in combination with process simulation tools are required. Post- or in-mold assembly processes, mechanical joining by screws or rivets, and adhesive bonding are state-of-the-art techniques for joining dissimilar materials such as metal and thermoplastics [R. Hoffschlag, Forschungsbedarf zum Fügen von Kunststoffen im Leichtbau und im Bereich erneuerbarer Energien (DVS-Berichte Band, Düsseldorf, 2012), p. 294; M. Gude, G. Meschut, M. Zäh, H. Lieberwirth, FOREL-Studie: Chancen und Herausforderungen im ressourceneffizienten Leichtbau für die Elektromobilität (2015)]. Specific restrictions can be found with the limited geometry flexibility, the use of an additional material and comparable long joining times. Hence, new joining solutions are needed. In this presentation, the use of thermal induced joining for metal and thermoplastic parts will be shown. These processes are characterized by short joining times and the substitution of glue, screws, or rivets. The key technology to enable high joint strengths is the material adapted surface modification. As a research result, the influence of physical and chemical pretreatment will be presented. It could be shown that metal ablation by high power lasers can efficiently generate a macroscopic surface structure, which enables mechanical fastening of the polymer at the metal surface. Depending on the materials to be joined, different kinds of heat inputs can be used. In this presentation, the joining by hotplates and by lasers will be introduced. It will be shown that an optimized surface pretreatment enables joints with a lap shear strength of 20 N/mm2 and more, depending on the material configuration

Additive Manufacturing of Titanium with Different Surface Structures for Adhesive Bonding and Thermal Direct Joining with Fiber-Reinforced Polyether-Ether-Ketone (PEEK) for Lightweight Design Applications

“…For this purpose, pins and grooves with trapezoidal cross sections were selected as interlocking structures. The geometries of the interlocking structures were adapted from a study by Klotzbach et al, in which the authors attained features with a similar shape by means of laser surface structuring [15]. The features' size was then adjusted to comply with the approximate attainable feature size resolution in electron beam melting.…”

“…In this study, thermal direct joining based on inductive heating was applied, which is well suited to joining metals and fiber-reinforced polymers due to the rapid heating [13]. The short process times result in a high economic efficiency of the technology [14][15][16]. The general principle of the process is illustrated in Figure 1.…”

Influence of Welding Temperature and Weathering on Inductive Welded Hybrid Joints Made of Steel and TP-FRPC

“…10 MPa. Klotzbach et al [12] used heating elements to join compressed air pre-treated steel with an adhesion agent coating to GF-PA6. The achieved bond strength is 30 MPa.…”

A Review on the Abrasive Water-Jet Machining of Metal–Carbon Fiber Hybrid Materials

“…At the same time, the performance of a surface texture can be fundamental for the correct joining of the materials. Klotzbach et al [10] propose the use of laser technology for the joining process between the metallic alloy and the composite material. Thus, laser can be used as a preliminary preparation in order to eliminate residues and improve the bonding area.…”