Additive Cladding for Stronger Metal-Plastic Structural Joints
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Solution Overview
Problem
Existing methods for joining metal and plastic materials do not achieve high enough strength for structural components, particularly in motor-vehicle structures, while also being cost-effective and lightweight.
Innovation Solution
A method involving the application of heat to press metal and plastic elements together, with a cladding of metal and/or plastic material applied using additive manufacturing technology, including a coarse and fine cladding with micro-ribs, and optional local quenching or heating to enhance mechanical properties, and the use of an uneven surface with asperities or adhesive for improved bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional joining methods (heat pressing with laser beam) are used to join metal and plastic elements, then the joint can be obtained with basic strength characteristics, but the strength is not high enough for structural components
Solution Approach 1:
The invention applies a cladding layer made of composite material (metal or plastic) over the joint area using additive manufacturing. This composite cladding reinforces the joint by combining materials with complementary properties, creating a hybrid structure that achieves the high strength required for structural motor-vehicle components while maintaining the original metal-plastic joint configuration
Solution Approach 2:
The uneven surface portion with asperities is created on the metal element before the joining process. This preliminary surface preparation enhances mechanical interlocking when the plastic material is softened and pressed against the metal surface, filling the asperity spaces to create a stronger bond before the actual heat pressing operation
2Strength
If additive manufacturing cladding is applied to enhance joint strength, then the mechanical strength significantly improves, but the process complexity increases
Solution Approach 1:
The invention combines the heat pressing joining process with additive manufacturing cladding application in an integrated sequence. The cladding is applied directly over the joint area after the initial heat pressing, merging two manufacturing operations into a coordinated process that enhances strength without requiring completely separate production lines or complex multi-step procedures
Solution Approach 2:
The additive manufacturing cladding is applied locally only at the joint area rather than over the entire component surfaces. This localized application targets the specific region needing reinforcement, reducing material consumption and process complexity while achieving the required strength enhancement precisely where the metal-plastic joint exists
3Weight of stationary object
If conventional joining methods are used, then the process is simple and cost-effective, but the joint weight cannot be optimized for reduced weight applications
Solution Approach 1:
The invention changes the physical and chemical parameters of the joint by applying a cladding layer with different material properties than the base materials. The additive manufacturing process allows precise control of cladding thickness, composition, and microstructure, optimizing the weight-strength ratio by selecting cladding materials and parameters that provide maximum strength enhancement per unit weight added
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method significantly enhances the mechanical strength of the joint without increasing weight, making it suitable for structural applications in motor-vehicle production with reduced costs.
Implementation Method 1
the heat being obtained for example with the aid of a laser beam
Implementation Method 2
Following the above mentioned application of heat a softening and in some cases even a local melting of the plastic material is generated
Implementation Method 3
a softening and in some cases even a local melting of the plastic material is generated, so that the latter fills the spaces between the asperities
Implementation Method 4
maintains this configuration after a subsequent cooling
Implementation Method 5
a method in which an energy source is used, such as a laser or plasma beam, to selectively melt layers of powders or wires of the metal material or plastic material
Implementation Method 6
applying a cladding of metal material and/or plastic material above said joint, by means of additive manufacturing technology
Implementation Method 7
the method can further comprise a step of local quenching obtained by feeding a cold fluid above the cladding layer, immediately after the application of the cladding. This operation can be carried out in order to provide an increase of the mechanical characteristics of a metal cladding
Implementation Method 8
the method can comprise a local heating step, obtained by feeding a hot fluid, immediately before or after the step of application of the cladding. This heating step has the function of causing a release of the inner stresses induced within the material during the process
Implementation Method 9
Also an object of the invention is that of providing a method for joining elements of different materials which can be easily adapted to motor-vehicle production lines of today and which accordingly does not involve high costs for being implemented
Data Source
AI summary
A joint between at least one element of metal material and at least one element of plastic material is obtained by pressing these elements in contact against each other, with a simultaneous application of heat. A cladding of metal material and/or of plastic material is applied above the joint by additive manufacturing technology.