Abstract
Generative hybridization enables the efficient production of lightweight structures by combining classic manufacturing processes with additive manufacturing technologies. This type of functionalization process allows components with high geometric complexity and high mechanical properties to be produced efficiently in small series without the need for additional molds. In this study, hybrid specimens were generated by additively depositing PA6 (polyamide 6) via fused layer modeling (FLM) onto continuous woven fiber GF/PA6 (glass fiber/polyamide 6) flat preforms. Specifically, the effects of surface pre-treatment and process-induced surface interactions were investigated using optical microscopy for contact angle measurements as well as laser profilometry and thermal analytics. The bonding characteristic at the interface was evaluated via quasi-static tensile pull-off tests. Results indicate that both the bond strength and corresponding failure type vary with pre-treatment settings and process parameters during generative hybridization. It is shown that both the base substrate temperature and the FLM nozzle distance have a significant influence on the adhesive tensile strength. In particular, it can be seen that surface activation by plasma can significantly improve the specific adhesion in generative hybridization.
Highlights
Published: 12 July 2021Multi-material structures are a target-oriented approach to produce highly lightweight structures, especially for the aviation and automotive sector
It was shown that penetration of the fused layer modeling (FLM) nozzle into the surface of the substrate could be advantageous for the bonding strength between the thermoplastic composite (TPC) sheet and the printed polyamide 6 (PA6) structure
The FLM nozzle temperature when melting the polymer filament using an FLM printer can be sufficiently high to allow the FLM nozzle to drive to negative distances, melting the surface in the process
Summary
Published: 12 July 2021Multi-material structures are a target-oriented approach to produce highly lightweight structures, especially for the aviation and automotive sector. Modern car body structures increasingly use intrinsic hybrid structures and combination processes, in which flat semi-finished products made of metal- or textile-reinforced thermoplastic are formed and functionalized using injection molding technology [2,3,4] This requires tooling systems that are very cost intensive and unsuitable for efficient production in the low volume range with a high number of variants. In order to be able to implement flexible manufacturing processes while at the same time achieving high resource efficiency, the use of additive manufacturing technologies is an ideal solution This allows the semi-finished products to be functionalized after shaping without additional tools in a generative hybridization process, as shown by [5,6] using fused layer modeling (FLM) and [7] using liquid resin print as well as [8,9,10,11] directly printing onto textile substrates via FLM. An essential part of the generative hybridization process of such multi-material structures is the joining of the various
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