Heterogeneous Data Joining Skills For Automotive Aluminum Die Castings

- Sep 16, 2018-

The variety of applicable materials is constantly expanding without the use of adhesives or joints to bond heterogeneous materials together.

The Japanese MEC company, which directly combines the "AMALPHA" skills of resin and metal, has increased the number of resin materials for this skill from the original five to 17. In terms of metal, in addition to aluminum alloy forging materials, aluminum alloy die-casting materials can be joined. After the addition of aluminum alloy die-casting materials, this skill is expected to be rapidly implemented in the automotive field where more die-casting parts are used.

The goal is "can be used anywhere"

In terms of metal, only aluminum alloy, stainless steel (SUS) and copper (Cu) materials were used. Now, aluminum alloy die-casting materials can be joined.

The symbols in the table indicate the joining conditions and the joint strength. ◎ indicates that joining can be performed by injection molding, in which the joint surface is not peeled off and the resin is damaged (the base material is damaged). ○ indicates hot press welding in which the base material is damaged during the tensile test. △ indicates that the bonding is performed by injection molding or hot pressing, but the bonding strength is low, and the bonding surface may fall off at a strength of about 1 MPa. "-" indicates that it has not been tested. That is, the resin labeled ◎ or ○ can be directly and firmly bonded to the metal.

Forming a recess on the metal surface

The bonding of the resin to the metal utilizes an "anchor effect" that can form a physical bond. The principle is that some fine pores are opened on the surface of the metal, and the molten resin is poured therein, and the resin is cooled and solidified, and the resin is hooked on the hole like an anchor, and cannot be pulled out.

The joining process is as follows. First, the metal is immersed in the degreasing liquid to remove the processing oil and rust adhering to the metal surface. The second step is to immerse the metal in an etchant (surface roughening agent) to roughen the surface of the metal to form fine pores. Then, the metal is immersed in an acidic solution, and the by-product (dirt) deposited on the surface of the metal is washed away, washed with water, and dried. Finally, the molten resin is written into the metal of the surface opening by methods such as injection molding, resin transfer molding, and hot press molding. After the resin is solidified, a joint of a resin and a metal is prepared.

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