Cheap and efficient way to weld metal and plastic

Michigan Engineering researchers have developed a method for welding metal and polypropylene, a lightweight plastic commonly used in automobiles.

Combining different materials, such as metal and plastic, is a desirable technique for the light-weighting of vehicles, however, the chemical composition of plastic makes it impossible to join to metal without adhesives and fasteners.

The team achieved this by using a thin material that they place between the metal and aluminum, providing a bridging that allows the two materials to join. They achieved this joining by using a frictional tool that applies heat and pressure to the two materials, creating a strong multi-material joint.

This development joins other metal and plastic welding processes developed by the team, offering an affordable light weighting solution for manufacturers.

This work was performed in the lab of Pingsha Dong, the Robert F Beck Collegiate Professor of Engineering and a professor of naval architecture and marine engineering.

Read more:

The research was detailed in two recent journal publications:
Publication: Journal of Manufacturing Processes
Paper: Joining of Metal and Non-Polar Polypropylene Composite through a Simple Functional Group Seeding Layer
Date: November 22, 2022

Publication: Journal of Materials Processing Technology
Paper: Enabling interfacial amorphous microstructure and high bonding strength in Al-Fe bimetallic components by a large-area solid-state additive manufacturing
Date: July 16, 2022

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[MichiganEngineering]

For more information, read the Q&A with Professor Pingsha Dong:

🔗Links to two recent journal publications related to this research have also been added to the description above.

[kundeleczek]

He :"We don't need any additional structure"

Also he :Add tape...

[MichiganEngineering]

Here is a response from the research team regarding the questions about tape:

"Thanks for watching! This is a good question. In material joining technologies, the "tape" is generally referred to as having adhesive on at least one side (sticky surface) of it but here we are not using any kind of adhesive or adhesive surface. Here we are using a thin film of functional material free from any adhesive, contrary to the "tape", to provide enough oxygen to coax the material to form the necessary chemical bond when exposed to heat and pressure."

🔗For a more detailed explanation about the functional material, as well as questions about the tensile strength of the bond and the polypropylene, please refer to the research articles linked to in the description.

[sreilly]

how does the tensile strength of the bond compare with the tensile strength of polypropylene?

[josephcoylejr.]

Interesting I was researching something similar as I am about to attempt to bond Tivar 88 to 120 mesh 304 stainless steel. Not exactly the same thing but theoretically I was going to apply heat above 400F and some pressure. Not sure if it will work but would be great if it does.

[TheKevinFanClub]

If that tape is what's adding the linkage. Then how is this different than using adhesives.

[adamegrafik]

This is more brazing than welding. Still, very cool.