REG: In-situ Joining of Thermoplastics and Their Composites to Metals in Net-Shape Processes, Hot-Melt, Filament Winding, Injection Molding, and Shrink Fitting

这是一项工程研究设备补助金，用于购买注塑机和感应加热装置。该设备将用于几个项目，包括热塑性聚合物结构粘合，热塑性塑料及其复合材料在净形工艺中与金属的原位连接，包括注塑成型，长丝缠绕和收缩配件，以及结合感应加热以提高工艺速度。本研究的主要目的是开发原位工艺，将热塑性复合材料与金属在净形状工艺中连接起来。将残余应力建模为工艺参数的函数。表面制备、固结过程中的接触压力、加热和冷却速度、在熔融和再结晶温度下的保持时间、结合线厚度和均匀性的影响，以及提高耐久性的阳极氧化将包括在工艺开发周期中。感应加热将用于瞬间和优先加热金属表面以进行粘合。研究结果将应用于长丝缠绕和注射成型。已知的表征技术，如x射线衍射（XRD）、差示扫描量热法（DSC）和扫描电子显微镜（SEM）将用于评估界面处的聚合物形态和结构。已经与一家工业合作伙伴达成合作安排，对聚合物和金属之间的接头进行规模测试和机械强度评估。该研究成果将应用于生物医学、汽车、航空航天等领域。预计这种塑料和金属之间的创新连接将大大缩短生产周期，从而降低总成本。考虑到原位连接能力，可以纳入进一步的新设计功能。

9500232 Ramani This is an Engineering Research Equipment Grant to purchase an injection molding machine and induction heating unit. The equipment will be used in several projects, including thermoplastic polymer structural bonding, in-situ joining of thermoplastics and their composites to metals in net-shape processes, that includes injection molding, filament winding and shrink fitting, and incorporation of induction heating to increase process speeds. The primary objective of this research is to develop in-situ processes to join thermoplastic composites to metals in net-shape processes. The residual stresses will be modeled as a function of the process parameters. The surface preparation, contact pressure during consolidation, heating and cooling rates, hold times at melt and recrystallization temperature, effect of bond line thickness and uniformity, and anodization to increase durability will be included in the process development cycle. Induction heating will be used to transiently and preferentially heat the metal surface for bonding. The results will be applied to filament winding and injection molding. Known characterization techniques such as x-ray diffraction (XRD), differential scanning calorimetry (DSC), and scanning electron microscopy (SEM) will be used to evaluate the polymer morphology and structure at the interface. Cooperative arrangements have been made with an industrial partner to do scale up testing and mechanical strength evaluation of the joints between polymer and metal. The results of this research will be applied to bio-medical, automotive and aerospace industries. It is anticipated that this innovative joining between plastics and metals will lead to major reductions in production cycle time which can reduce the total cost. Further new design features can be incorporated taking into account in-situ joining capabilities.