An alternative additive manufacturing-based joining method to make Metal/Polymer hybrid structures

Abstract

Fused Deposition Modeling with Polypropylene filament was employed to make a lap joint between Polypropylene and pre-punched Al-Mg alloy sheets, in the form of bonds between the polymeric substrate and the additive part and mechanical lock between the additive part and aluminum base sheet. Effects of the joint interface area (hole diameter of 5–13 mm) and preheating of the substrates (room temperature, 50 and 90℃) were investigated on the mechanical properties of the joints. Peak load in the tensile-shear and cross-tension tests increased with enhancement of the joint interface area (up to ˜280 N and ˜160 N, respectively). Higher joint strength in the tensile-shear test compared to the cross-tension test was discussed at the light of the failure locations in the tests. Preheating of the substrates increased the joint strength via improvement in the bonds between the polymer sheet and the additive part and increase in the adhesion force between the printed layers.