Fundamental Process Design and Characterization of Additively Manufactured Polymer-Metal Joints

Abstract

Automotive, aerospace, electronics, and medical device manufacturers are leveraging the potential of combining polymer and metals to produce highly efficient components. The motivation is the lightweight and compact nature of parts produced with fewer assembling components. Despite the growing need, the different chemical and physical properties constantly challenge polymer bonding to metals. The well-known techniques of bonding polymers to metals include adhesive bonding, mechanical fastening methods, and weld-based techniques such as friction spot joining ultrasonic bonding. However, these joining methods have limitations related to geometrical design, joint configuration, safety, and reliability of complex components. The choice of an appropriate joining method is of great significance for increased functional integration in the assembly of parts and improved efficiency and safety. Additive manufacturing is the newest technological innovation that has been proposed to enable the combination of polymers and metals. The 3D printing method provides enhanced creation of intricate designs, offers process flexibility, and superior manufacturing control compared to other bonding techniques such as laser joining, ultrasonic joining, and friction spot joining. In light of these developments, the main aim of this paper is to present the fundamentals of designing, testing, and characterizing polymer-metal joints. In this preliminary work, the use of Acrylonitrile butadiene styrene (ABS) and En AW 6060 aluminium alloy in the process will be justified, the international standards for designing and testing polymer-metal joints will be established, and the effect of the metal surface modification on the joint strength will be determined. It is expected then that the deductions made from the aforementioned objectives will form a foundation of ongoing research work, whose results will be documented in future publications. Keywords—Additive Manufacturing, Joining, Metals, Polymers