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Cast aluminium - CFRP composite components with transition layer of a high performance plastic

: Clausen, J.; Auwera, R. van der; Lardong, M.C.; Pille, C.; Wöstmann, F.J.; Busse, M.

Hausmann, J.M.; Siebert, M. ; Deutsche Gesellschaft für Materialkunde e.V. -DGM-, Oberursel:
Euro Hybrid Materials and Structures 2014. Proceedings CD-ROM : International conference. 10 - 11 April 2014, Stade, Germany
Stade: DGM, 2014
ISBN: 978-3-88355-402-0
Conference Euro Hybrid Materials and Structures <2014, Stade>
Fraunhofer IFAM ()

High-performance plastics were implemented as transition structures to join carbon fibre reinforced polymers (CFRP) and aluminium using high pressure aluminium die casting techniques. The transition structure was established by a plastic injection moulding process of polyetheretherketone (PEEK) on different CFRP elements with both an epoxy based matrix and a PEEK based matrix prior to the aluminium die casting. It is shown through micrographic sections that an adhesive bond between the composite and the transition zone material is established. In the contact zone of PEEK and the aluminium die casting alloy different degradation grades of the plastic evolve. Outgassing of the plastic results in gas pockets at the PEEK-aluminium interface depending on the thermal impact. The isolating effect of the polymeric layer prevents the PEEK based matrix of the CFRP components from delamination, whereas the epoxy based matrix does not withstand the thermal load while casting the aluminium. It is found that the quality of the transition zone depends on the processing of the application of the PEEK based transition structure onto the CFRP surface. The aluminium wall thickness surrounding the transition zone as the PEEK layer thickness both have an impact on the interfaces between the join partners.