Abstract
The metal housing is typically jointed with plastic fittings by conventional gluing method or embedding injection molding to produce this type of devices. We propose to improve this new technique with more practical approach. In plastic-aluminum substrate dissimilar joining, the 5052 aluminum plate coarsening process was performed to increase the porosity of the permeable dissimilar phase. The ABS polymer plus carbonized rice husk powder was later induced or deposited on the microstructure to improve the bonding effect. The plastic -aluminum substrate dissimilar joining is completed by the final step of ultrasonic welding. The finished substrate will be tested on the properties of tensile strength to ensure its quality. According to the simulation analysis and measuring results, the maximum temperature between the interface of ABS polymer and 5052 aluminum alloy is about 400~450 °C during ultrasonic welding, which can make the surface of ABS polymer to be melted. Furthermore, after drilling micro-hole array and covering ABS plus carbonized rice husk powder, the 5052 aluminum alloy shows better joining effect with ABS polymer sheet by ultrasonic welding. This improved approach does not require mold or injection molding machinery to produce the high quality plastic -aluminum bonding parts.
Highlights
It is placed into a mold and subjected to injection molding for plastics to enter the nano-holes and solidify, thereby achieving the bonding of metal and plastic
An aluminum alloy surface with a micro-hole array was placed into mixed powder of acrylonitrile butadiene styrene (ABS) and carbonized rice husk, after which it was subjected to ultrasonic welding
These results indicate that under sufficient bonding conditions, the fracture positions of the stretched test pieces were all located at the ABS base material instead of on the bonding interface, demonstrating a satisfactory bonding effect
Summary
It is placed into a mold and subjected to injection molding for plastics to enter the nano-holes and solidify, thereby achieving the bonding of metal and plastic. The process involves high temperature and high pressure effects that can deform the thin metal plates, whereas the use of plastic molds and injection molding machines increases production costs. Welding is another viable bonding method, with the early application of ultrasonic welding being mainly used for the bonding of plastic materials; it has been used to bond dissimilar aluminum alloy and plastic materials in recent years 【 6,7 】. Rice husks are low-priced agricultural waste from rice grain production, and mixing them with plastic following their carbonization to form composite materials can improve part strength
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