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Prefinished metal polymer hybrid parts

Einbaufertige Hybridbauteile
: Kühnert, Ines; Gedan-Smolka, Michaela; Fischer, Matthieu; Scholz, Peter; Landgrebe, Dirk

Kroll, Lothar (Ed.):
3rd International MERGE Technologies Conference 2017. Conference Proceedings : IMTC 2017 Lightweight Structures; Merge Technologies for Multifunctional Lightweight Structures; 21st - 22nd September 2017, TU Chemnitz
Zwickau: Verlag Wissenschaftliche Scripten, 2017
ISBN: 978-3-95735-066-4
ISBN: 3-95735-066-2
International MERGE Technologies Conference Lightweight Structures (IMTC) <3, 2017, Chemnitz>
Fraunhofer IWU ()
assembly injection molding; chemical bonding; forming; interface design; polymer-metal hybrid; powder coating; Hybridbauteil; Metall-Kunststoff-Verbund; Grenzfläche; Pulverlack; Leichtbau; Spritzgiessen; Verbundfestigkeit

In this study, the shaping and assembly behavior of adhesive polymer-metal-composites was investigated in an international cooperation using two step curable uretdione-polyester-based powder coatings (IPF development [1,2]) which acts simultaneously as a reactive adhesive agent and as a high quality surface finish. To create the composite, a thermoplastic polyurethane (TPU) layer with good compatibility to the powder coating was over-molded onto a powder coated aluminum substrate. A polyamide (PA6) layer was over-molded on to the TPU layer to create a stiff composite structure with possibilities for further functionalization. The TPU-layer in between the metal substrate and the polymer top layer acts as a stress and strain compensation layer. These loads are caused by thermal expansion (under fluctuating temperatures) and external forces/deformation. Another key feature of the composite is the innovative process chain. The powder coating can resist high deformation and therefore the coating is suitable for a future application on to a metal substrate using a coil coating procedure. In addition, the coil could be easily implemented into a production line as a semi-finished product. The prefinished coated metal substrate could be formed (e.g. incremental forming, deep drawing) and inserted in the over-molding procedure. This overall shortened process chain allows not only an effective fabrication of pre-coated semi-finished materials and polymer-metal-joints in high quantities by saving process steps (e.g. cleaning steps, glue application) but also a higher versatility in the following composite production.