HC Plastics News:
To reduce the weight of metal chassis components, a high performance manufacturing process was developed.
With the VESTAMELT® Hylink adhesive, the multiform process simultaneously achieves the formation and bonding of long-fiber reinforced thermoplastics and sheet metal, and reduces the weight of the vertical and horizontal car control arms used as demonstration components by approximately 20%.
This longitudinal control arm made of high-strength steel and 40% long glass-reinforced thermoplastic with VESTAMID® PA12 adhesive replaces solid metal parts and reduces weight by approximately 20%.
The metal components and plastic components in the hybrid material component are typically joined together by means of friction or shape-fitting components such as screws, rivets, etc., or joined together by overmolding and insert molding.
Now a new production process multiform covers the forming of sheet metal and the formation of long fiber reinforced thermoplastics (LFT), but the challenge is to consider the rib and the variable wall thickness distribution of the fiber reinforced plastic. It is necessary to bond with VESTAMELT® Hylink adhesive technology.
In order to demonstrate this process, the longitudinal and lateral control arms of the rear axle of a famous German car manufacturer were selected as demonstration pieces. They were originally made of solid metal and are now produced by multiform process.
Under the direction of Professor X.Fang of the University of Siegen, Germany, the researchers designed, simulated/calculated and tested the parts made with the new FRP-metal hybrid material.
With the completion of these and subsequent process developments, a new solution emerged with high-strength steel and long-glass reinforced thermoplastics, while VESTAMELT® Hylink adhesives were used to bond dissimilar materials.
For the purposes of demonstration, polyamide 6, polyamide 610 and polyamide 12 containing 40% long glass fibers were used in the production of longitudinal control arms.
In the multiform process:
â– First extruding a long glass fiber reinforced compound produced by Weber Fibertech to obtain a formable semi-finished product;
â–The semi-finished product is then placed in a mold together with a preheated metal sheet coated with VESTAMELT® Hylink (transferred in molten state);
In a one-step production process, the two components are press-formed and bonded together.
The mold has a concave structure for rib and metal forming.
This integrated process of steel and LFT bonding thanks to VESTAMELT® Hylink adhesive allows the parts to be removed from the mold directly into the bonded composite part.
This production method can replace the traditional multi-step production process more technically and economically.
By combining VESTAMELT® Hylink adhesives with two different types of materials, LFT, the thickness of the steel plate can be reduced by more than 1 mm, whereby the weight of the longitudinal and lateral control arm variants can be reduced. 20%.
Editor in charge: Yao Chunlin
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