PMJOIN

Development of a Direct Laser Joining of hybrid Plastic-Metal components for industrial applications

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 Obiettivo del progetto (Objective)

'Automotive industry is looking for reducing energy consumption by using lightweight structures instead of some metal parts. This fact is causing the introduction of plastic sections. But, as metals cannot be excluded as fundamental material in many applications; many products are made of multi-components where several types of materials are introduced. Up to date, the stable joining of plastics and metals is not easy and takes place by methods as adhesive bonding or mechanical joining, that involve a large number of production steps. The present project aims to overcome their disadvantages trough the development of a new innovative joining concept for Plastic and Metal materials using a direct non-contact laser joining process without extra filler, adhesive bonds or mechanical union but that offers a robust physical and mechanical bonding and ensures the integrity of the structure. The PM laser joint herein presented is led to offer higher process flexibility compared to mechanical joints especially through the use of flexible beam guiding systems. Compared to adhesive bonding solutions it can be much faster with high joint resistance and same flexibility but without contaminant risks. In addition, the shortening of the process chain will lead to a more economical and faster production. Another important aim of this project fits with a general requirement for technical components which is to achieve flexible automatic joining prototypes for dissimilar plastic-metal materials with short cycle times and a broad field of applications. The consortium counts with three large companies like FAURECIA, PSA and VALEO as end users mainly dedicated to automotive sector, LASEA as SME laser source integrator and ANDALTEC as high-tech SME supporting innovation in the plastic field. The consortium is complemented with ILT, TEKNIKER and ARMINES, research Centers of excellence in laser, manufacturing and material characterization topics.'

Introduzione (Teaser)

An EU-funded project focuses on developing an innovative system for joining metals and plastics or plastic composites together using laser technology. Project results should have important implications for automakers seeking to lower emissions and improve fuel consumption.

Descrizione progetto (Article)

In a continuing effort to reduce energy consumption, the automotive industry is increasingly looking at plastics or composites to replace the heavier metal parts in an automotive structure. This drive has prompted the need to design new systems for joining plastics to metals that are robust in an industrial environment.

Current methods for stable joining of plastics and metals include adhesives, mechanical joints or overmoulding that involve a large number of assembly operations.

The EU-funded http://www.pmjoin.eu/ (PMJOIN) (Development of a direct laser joining of hybrid plastic-metal components for industrial applications) project is overcoming the drawbacks of state-of-the-art methods by developing a new innovative thermal joining concept for metals and plastics. PMJOIN is investigating a new laser-based process that eliminates the need for additional materials, adhesives or other bonding elements.

Thanks to use of flexible beam guiding systems, the laser joining system will offer greater flexibility compared to mechanical joining and adhesive bonding. Being much faster and involving higher joint resistances, this new process will also significantly reduce environmental impact.

Extensive research efforts are highlighting strategies to modify the metal surface for improving the joint between the plastic and metal. Selection of suitable laser sources for structuring and joining is also essential.

Design of suitable optical elements based on diffractive lenses or scanning optics should allow obtaining different beam shapes or heating geometries according to material and application requirements.

So far, project partners have produced models able to predict the joint performance through optimising the mechanical behaviour of the joined structure. In addition, they have identified different polymer-metal combinations for eight applications that mainly relate to automotive lighting and structure applications.

Another task has been to successfully demonstrate the possibility of performing both structuring and joining operations with the same low-power laser source.

PMJOIN has spurred a new wave of research aimed at improving metal-plastic assemblies to ultimately help decrease vehicle weight. Furthermore, the project will lead to an increase in the speed of joining processes on the assembly line, translating to more economic and efficient production.