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Abstract
In this, work, metal inserts were joined with polyamide 6 by using the injection-molding technique. The metal parts, made of steel grade DC 04, were mechanically interlocked with polyamide 6 (PA6) by rivets as a mechanical connection between both components in the form of s polymer filling the holes in the metallic parts. The mechanical-interlocking joints made of steel/PA6 were mechanically tested in a tensile-lap-shear test. The damage behavior of the joined materials in relation to rivet number and position on the metal plate was studied. The observation of rivet deformation was also conducted by infrared IR thermography. The study showed that, for polymer–metal joined samples with fewer than three rivets, the destruction of rivets by shearing meant sample damage. On the other hand, when the polymer–metal joint was made with three or four rivets, the disruption mechanism was mostly related to the polymer part breaking. The maximal values of the joint’s failure force under tensile-shear tests were achieved for samples where three rivets were used. Moreover, strong correlation was found between the surface temperature of the samples and their maximal force during the tensile-lap-shear test.
Highlights
Polymer–metal hybrid structures are promising energy-saving materials for manufacturing lightweight and high-mechanical-strength components, mainly for aerospace, automotive, railway, and household appliances
The innovative solutions are mainly focused on microstructuring the metal surface before it comes in contact with the melted polymer, for example, by plasma etching, laser microabrading, and with the use of sophisticated joining processes like friction spot welding (FSW), friction riveting, joining by injection clinching, and ultrasonic joining—methods that are described below
The creation of polyamide 6 (PA6)/talc composites was described in the previous paper [27], dealing with analysis of polymer flow at the injection mold with a metal insert, where talc particles were used as markers of molten-polymer streaming vectors
Summary
Polymer–metal hybrid structures are promising energy-saving materials for manufacturing lightweight and high-mechanical-strength components, mainly for aerospace, automotive, railway, and household appliances. The joining processes of advanced hybrid materials usually involves mechanical coupling, while the molten polymer is formed by joining polymeric rivets in the through-holes of the metallic part [1,2,3,4]. With the production of metal–polymeric parts by means of injection molding, their features depend on those of the adhesion bonding. In this case, the creation of the surface topography of metallic parts using chemical etching or sandblasting with chemical functionalization is crucial for coupling quality [5,6,7,8,9]. The innovative solutions are mainly focused on microstructuring the metal surface before it comes in contact with the melted polymer, for example, by plasma etching, laser microabrading, and with the use of sophisticated joining processes like friction spot welding (FSW), friction riveting, joining by injection clinching, and ultrasonic joining—methods that are described below
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