Technische Universität Chemnitz
Owing to the demand for improved load resistant and low-cost lightweight structures in automobile and aerospace applications, a trend in the production of hybrid metal/plastic material compounds has substantially increased. By producing such hybrid compounds, the properties of both the plastic and metal part are optimally combined together, and it results in attaining the synergistic effects which cannot be fulfilled by either of them separately. In this research work, three-dimensional (3D) macroscopic transition wire structures (strucwire®) are used in the metal/plastic interface to generate a graded property transition between the sheet metal and the plastic component that allow significantly higher loads on the hybrid compounds. A galvanized steel sheet (HX340LAD+Z100) and transition wire structures were mechanically blasted to improve the interlocking mechanism before they were brazed together using ZnAl based brazing alloy. In particular, the Zn layer on the galvanized steel sheets was used to join the transition structures with or without electroplated Zn coatings on the transition structures. The brazed metal components were then injection molded with short glass-fiber reinforced polyamide through the permeable transition wire structures to produce the hybrid metal / plastic compounds. New insights into the shrinkage behavior of glass-fiber reinforced thermoplastics in permeable transition structures as well as the alignment behavior of the short fibers when flowing through the structures depending on the materials, the permeability and the process-technological parameters were analyzed. In addition, the microstructural, mechanical and intermetallic phase characteristics of the produced hybrid compounds were evaluated using light microscopy, shear tests and scanning electron microscopy respectively.
Abstract
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