YBRIDIO

Novel technologies for dissimilar materials joining

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 Obiettivo del progetto (Objective)

'The requirements of innovation and efficiency are pushing industrial manufacturing methods to a new stage, where novel materials and components with enhanced properties are required. Polymers and polymer based composites are able to provide strength, light weight, corrosion resistance, impact resistance, etc. which are highly demanded from advanced technological sectors such as automotive, aerospace, electronics, consumer goods and others. For this reason the main objective presented in this project is the development of innovative and reliable thermal joining methods to join dissimilar materials, such as metal-plastic hybrid parts, with the aim to produce high quality joints between dissimilar materials, ensuring the integrity of the structure throughout the design, production and life cycle performance. Therefore, Ybridio is focused on thermal joining methods, specifically laser transmission joining (LTJ) and induction joining (IJ), which have demonstrated excellent potential to be implanted in industry. Both techniques deliver the energy directly to the base material and transmit the heat by conduction to the polymer part, so that the entire surfaces of both materials are attached to each other without any adhesive. The Ybridio project aims to achieve the following results: •Development of innovative and reliable new thermal joining techniques to join two or more different types of materials creating hybrid structures, such as metal with polymer and with composite laminates •Improvement of the characteristics of structures and components, combining and complementing the properties of each material •Simplification of industrial plants and processes to reduce manufacturing cost •To create a specific control system based on IR and NIR cameras, to ensure the quality of the components during the manufacturing process •Recycling and environmental impact: thermoplastic-metal joints can be disassembled easily by applying heat again which allows easy separation'

Introduzione (Teaser)

Polymer-based composites provide higher strength, lower weight, and better corrosion and impact resistance compared to conventional metal materials. Novel thermal joining processes to bond them with metals will expand applications and benefits.

Descrizione progetto (Article)

The advantages of polymers and their composites are important across numerous fields, including transport, aerospace and energy as well as consumer goods and electronics. However, the polymer-based materials typically form part of a whole that still includes metal components, meaning that suitable joining technologies are required.

Given the strategic importance to the European economy of creating hybrid components, the EU is funding the http://ybridio.eu/ (YBRIDIO) (Novel technologies for dissimilar materials joining) project focused on advanced thermal joining methods. Thermal bonding has the ability to entirely join the surfaces of thermoplastic materials and metals without adhesives or mechanical joints, for simpler and more cost-effective processes. Further, heating at the end of service life enables easy separation of components and disassembly for recyclation.

The team is seeking important breakthroughs in laser transmission joining and induction joining, including advances in innovative materials and composites, high-speed processing and process control. Both methods rely on heating of the base metal materials and transmission of the heat by conduction to the polymer part.

Already at the end of its first 18 months, the project is well on its way to delivering on those goals. Researchers started off by evaluating metal and composite materials for their compatibility. Having chosen promising hybrids, investigators then focused on the definition of processing parameters for each joining method as well as the optimal joint configuration to increase joint strength of sand-blasted parts. Scientists have now designed a clamping device for the laser joining process and temperature control systems for both methods.

Results have been presented at three fairs and a conference workshop. In the end, YBRIDIO's thermal joining technology for metals and polymer-based composites will enable the use of thin-walled plastics and long fibre-reinforced components as alternatives to metals. The technology will facilitate substantial reductions in materials waste. Applications in the transport sector will also enable important reductions in operating costs and emissions. Given the global market for hybrid components, the thermal joining technology is expected to have major benefits for the EU economy in a time of economic crisis.