Details
| Original language | English |
|---|---|
| Article number | 100928 |
| Pages (from-to) | 4537-4555 |
| Number of pages | 19 |
| Journal | International Journal of Advanced Manufacturing Technology |
| Volume | 137 |
| Issue number | 9 |
| Early online date | 25 Mar 2025 |
| Publication status | Published - Apr 2025 |
Abstract
Hybrid materials enable innovative and technologically advantageous lightweight design solutions, especially the efficient combination of metals and polymers is a promising approach. This contribution addresses an additive manufacturing (AM) process with polymers on the surface of foamable extruded aluminium profiles. The aim is to individualise aluminium profiles with locally applied polymer components using the foam structure as a mechanical bonding interface. The bond strength of hybrid aluminium foam-polymer composites fabricated via screw extrusion additive manufacturing (SEAM) is investigated and the influence of the key process parameters as well as the properties of the aluminium foam structures are taken into account. Additionally, X-ray microscopy is used to analyse the pore structure, evaluating the pore size distribution, the wall thickness, and the pore filling. The material- and process-dependent bond strength is determined from lap-shear and cross-tension tests. A ductile failure of the specimens was detected, which is caused by mixed failure modes such as cohesive failure and adhesive failure in the polymer and in the aluminum. By minimising the distance between the extruder nozzle and the aluminium foam, the samples with the highest adhesive strength of 5.4 MPa in the cross-tensile test and 7 MPa in the lap-shear test were produced. An inhomogeneous pore distribution shows the highest influence on the tested bond strength, which results in a large scattering of the maximum detected testing force. The aluminium foam-polymer composites show potential for overcoming the problem of joining dissimilar materials to produce hybrid structural components, which could enable further advances for these types of components.
Keywords
- Additive manufacturing, Aluminium foam, Bond strength, Metal-polymer hybrid components, X-ray microscopy
ASJC Scopus subject areas
- Engineering(all)
- Control and Systems Engineering
- Computer Science(all)
- Software
- Engineering(all)
- Mechanical Engineering
- Computer Science(all)
- Computer Science Applications
- Engineering(all)
- Industrial and Manufacturing Engineering
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In: International Journal of Advanced Manufacturing Technology, Vol. 137, No. 9, 100928, 04.2025, p. 4537-4555.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Bond strength analysis in additive manufacturing of polymer structures on aluminium foam
AU - Timmann, Frederic
AU - Schäfke, Florian Patrick
AU - Hürkamp, André
AU - Wacker, Christian
AU - Klose, Christian
AU - Maier, Hans Jürgen
AU - Dröder, Klaus
N1 - Publisher Copyright: © The Author(s) 2025.
PY - 2025/4
Y1 - 2025/4
N2 - Hybrid materials enable innovative and technologically advantageous lightweight design solutions, especially the efficient combination of metals and polymers is a promising approach. This contribution addresses an additive manufacturing (AM) process with polymers on the surface of foamable extruded aluminium profiles. The aim is to individualise aluminium profiles with locally applied polymer components using the foam structure as a mechanical bonding interface. The bond strength of hybrid aluminium foam-polymer composites fabricated via screw extrusion additive manufacturing (SEAM) is investigated and the influence of the key process parameters as well as the properties of the aluminium foam structures are taken into account. Additionally, X-ray microscopy is used to analyse the pore structure, evaluating the pore size distribution, the wall thickness, and the pore filling. The material- and process-dependent bond strength is determined from lap-shear and cross-tension tests. A ductile failure of the specimens was detected, which is caused by mixed failure modes such as cohesive failure and adhesive failure in the polymer and in the aluminum. By minimising the distance between the extruder nozzle and the aluminium foam, the samples with the highest adhesive strength of 5.4 MPa in the cross-tensile test and 7 MPa in the lap-shear test were produced. An inhomogeneous pore distribution shows the highest influence on the tested bond strength, which results in a large scattering of the maximum detected testing force. The aluminium foam-polymer composites show potential for overcoming the problem of joining dissimilar materials to produce hybrid structural components, which could enable further advances for these types of components.
AB - Hybrid materials enable innovative and technologically advantageous lightweight design solutions, especially the efficient combination of metals and polymers is a promising approach. This contribution addresses an additive manufacturing (AM) process with polymers on the surface of foamable extruded aluminium profiles. The aim is to individualise aluminium profiles with locally applied polymer components using the foam structure as a mechanical bonding interface. The bond strength of hybrid aluminium foam-polymer composites fabricated via screw extrusion additive manufacturing (SEAM) is investigated and the influence of the key process parameters as well as the properties of the aluminium foam structures are taken into account. Additionally, X-ray microscopy is used to analyse the pore structure, evaluating the pore size distribution, the wall thickness, and the pore filling. The material- and process-dependent bond strength is determined from lap-shear and cross-tension tests. A ductile failure of the specimens was detected, which is caused by mixed failure modes such as cohesive failure and adhesive failure in the polymer and in the aluminum. By minimising the distance between the extruder nozzle and the aluminium foam, the samples with the highest adhesive strength of 5.4 MPa in the cross-tensile test and 7 MPa in the lap-shear test were produced. An inhomogeneous pore distribution shows the highest influence on the tested bond strength, which results in a large scattering of the maximum detected testing force. The aluminium foam-polymer composites show potential for overcoming the problem of joining dissimilar materials to produce hybrid structural components, which could enable further advances for these types of components.
KW - Additive manufacturing
KW - Aluminium foam
KW - Bond strength
KW - Metal-polymer hybrid components
KW - X-ray microscopy
UR - http://www.scopus.com/inward/record.url?scp=105001037579&partnerID=8YFLogxK
U2 - 10.1007/s00170-025-15326-z
DO - 10.1007/s00170-025-15326-z
M3 - Article
AN - SCOPUS:105001037579
VL - 137
SP - 4537
EP - 4555
JO - International Journal of Advanced Manufacturing Technology
JF - International Journal of Advanced Manufacturing Technology
SN - 0268-3768
IS - 9
M1 - 100928
ER -