Practical and simulative analysis of microform-fit in-mould assembly plastic/metal composites with regard to structural filling and the resulting material properties

• Applicant: Professor Dr.-Ing. Christian Hopmann
• Subject Area: Plastics Engineering ; Mechanical Properties of Metallic Materials and their Microstructural Origins ; Thermodynamics and Kinetics as well as Properties of Phases and Microstructure of Materials
• Term: since 2023
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 528646743

Plastic/metal hybrid components can achieve weight-reduced and cost-efficient products with high functional integration by combining the specific material advantages. However, the creation of the material composite poses a challenge. Through the innovative joining approach of the micro-form-fit joint, i.e. the back-moulding of microstructures applied over a large area, the advantages of the form-fit, such as material independence, can be combined with the advantages of the material-fit, such as the avoidance of stress peaks or the enabling of media tightness. So far, there are no design guidelines available in the literature for this joining approach depending on the structure geometry, arrangement and the used moulding compound. This is mainly due to the microstructure geometry not being fully defined due to the laser process and the challenges in calculating and simulating the filling of microstructures. However, the filling of the microstructures has a significant influence on the bond strength, which is why this is to be fundamentally and comprehensively investigated as part of the research project. In addition to the filling of the microstructures in the injection moulding process, the resulting material properties such as the crystallisation of the plastic in the area of the microstructures will also be examined. The aim is to predict the structure filling as well as the material properties as a function of the structure geometry, the used compound, the used sheet material, the injection moulding process parameters and the moulded part geometry. For this purpose, both comprehensive practical analyses are carried out and various simulative approaches are considered.

• DFG Programme: Research Grants