Polymer coating material for innovative reversible dissimilar composite-metal joining for automotive applications

Abstract

Copyright © 2022 Bahrami et al. While the cost of composites has dropped over the past decade, the effective joining of these materials to conventional metal parts in the automotive sector remains a significant challenge. Existing joining solutions present several limitations, with major manufacturers inclined to use mechanical fasteners or adhesive bonding. In this study, Polymer Coated Material (PCM) joining process is adapted for thermoplastic composite to metal assembly. This joining method uses induction welding to join a thermoplastic composite to a metallic substrate pre-coated with a compatible thermoplastic polymer film. Compared to mechanical fastening, PCM does not induce stress concentrations in the parts, and as the materials are not pierced, the risk of water damage is reduced. Compared to adhesives, PCM solution is not subject to curing times or shelf-life restrictions. Furthermore, the use of PCM enables easy recyclability of the parts; at the end-of-life, the parts can be disassembled through a reversal heat process.