The suitability of various polymer-powder spraying technologies for coating of metal stampings used in polymer metal hybrid (PMH) load-bearing automotive component applications is considered. Firstly, a comprehensive review is provided of the public-domain literature dealing with various powder-coating processes suitable for the fabrication of an overlay within a U-shaped body-in-white (BIW) metal stamping structural component which will be subsequently hybridized using the polymer-to-metal direct adhesion injection molding process. After the product (overlay coating) requirements and the capabilities and attributes of the various processes were identified, a set of engineering design tools were used to identify the screen-out non-suitable processes and to rank the remaining ones. The suitability of the spraying technologies is assessed with respect to a need for metal stamping surface preparation/treatment, their ability to deposit the polymeric material without significant material degradation, the ability to selectively overcoat the metal stamping, the resulting magnitude of the polymer-to-metal adhesion strength, durability of the polymer/metal bond with respect to prolonged exposure to high-temperature/high-humidity and mechanical and thermal fatigue service conditions, and compatibility with the automotive BIW manufacturing process chain. A detailed cost analysis is carried out while assessing the criteria used for ranking the candidate powder-coating processes. The analysis revealed that while each of the spraying technologies has some limitations, the cold-gas dynamic-spray process appears to be the leading candidate technology for the indicated applications. While no public domain data exist regarding the ability of the cold-gas dynamic-spray process to deposit nylon, a transient non-linear computational analysis carried out in the present work suggested that such a process is feasible.
Selection of the spraying technologies for over-coating of metal-stampings with thermo-plastics for use in direct-adhesion polymer metal hybrid load-bearing components
Auswahl des Spritzverfahrens zur Beschichtung von Blechteilen mit Thermoplasten für direkt verklebte tragende Polymer-Metall-Hybridbauteile
Journal of Materials Processing Technology ; 198 , 1-3 ; 300-312
2008
13 Seiten, 6 Bilder, 6 Tabellen, 13 Quellen
Aufsatz (Zeitschrift)
Englisch
Pulverspritzen , Beschichten mit Kunststoff , thermoplastisches Pulver , Hybridtechnik , Hybridverbundwerkstoff , Spritzgießverfahren , tragendes Bauteil , Karosseriekomponente , Literaturübersicht , Verfahrenseignung , Verfahrensauswahl , Pulverbeschichten , Stanzteil , Machbarkeitsuntersuchung , Haftfestigkeit , Lebensdauer , Dauerschwingfestigkeit , Ermüdungswiderstand , thermische Ermüdung , Kostenanalyse , Nylon
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