Injection overmolding of polycarbonate-aluminum alloys hybrid structures
Autor(a) principal: | |
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Data de Publicação: | 2023 |
Tipo de documento: | Tese |
Idioma: | eng |
Título da fonte: | Repositório Institucional da UFSCAR |
Texto Completo: | https://repositorio.ufscar.br/handle/ufscar/18217 |
Resumo: | Overlap joints between polycarbonate (PC) and aluminum alloys AA6061 and AlSi10Mg were manufactured by injection overmolding and evaluated regarding the interfacial structure and mechanical performance. The injection overmolding parameters; barrel temperature, injection speed and holding pressure were optimized through a design of experiments, using AA6061 inserts machined from an rolled sheet and laser surface textured. The injection molding parameters studied showed a positive effect on the filling of the grooves on the metal surface. The ultimate lap-shear force (ULSF) was used as a response and the values correlated to the filling of the polymer into the grooves of the metal surface, the molding conditions and the rheology of the polymer. Additionally, with the aid of design of experiments, AlSi10Mg inserts were produced by laser powder bed fusion (L-PBF), and their surfaces were structured with submillimetrical dimensions features on the metal surface, so-called, inkpot-like, mushroom-like and lattice structures. Afterwards, the metal inserts were hybridized with PC via injection overmolding and the interfacial strength were evaluated. PC/AA6061 and PC/AlSi10Mg joints exhibited outstanding joining strength of 7.2 MPa ± 0.5 MPa and 20.5 MPa ± 3.8 MPa, respectively. Fracture analysis through optical and scanning electron microscopies and digital image correlation (DIC) was used to elucidate the joint failure mechanisms. In dynamic fatigue testing, joints exhibited fatigue life close to 30% ULSF, demonstrating excellent mechanical durability. In addition, PC/AA6061 joints showed excellent hygrothermal stability. The findings add to the comprehension of the manufacturing, mechanical behavior and durability of injection overmolded polymer-metal hybrid structures. |
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Oliveira, Gean Henrique Marcatto deCanto, Leonardo Brescianihttp://lattes.cnpq.br/7287108960864123Amancio-Filho, Sergio Tragliahttp://lattes.cnpq.br/7609614295379921http://lattes.cnpq.br/2892871093566684https://orcid.org/0000-0002-4403-3643https://orcid.org/0000-0002-4138-005Xhttps://orcid.org/0000-0002-1886-13493951ebea-00e9-4748-bf28-50d3a03e7bb52023-06-29T16:21:55Z2023-06-29T16:21:55Z2023-03-24OLIVEIRA, Gean Henrique Marcatto de. Injection overmolding of polycarbonate-aluminum alloys hybrid structures. 2023. Tese (Doutorado em Ciência e Engenharia de Materiais) – Universidade Federal de São Carlos, São Carlos, 2023. Disponível em: https://repositorio.ufscar.br/handle/ufscar/18217.https://repositorio.ufscar.br/handle/ufscar/18217Overlap joints between polycarbonate (PC) and aluminum alloys AA6061 and AlSi10Mg were manufactured by injection overmolding and evaluated regarding the interfacial structure and mechanical performance. The injection overmolding parameters; barrel temperature, injection speed and holding pressure were optimized through a design of experiments, using AA6061 inserts machined from an rolled sheet and laser surface textured. The injection molding parameters studied showed a positive effect on the filling of the grooves on the metal surface. The ultimate lap-shear force (ULSF) was used as a response and the values correlated to the filling of the polymer into the grooves of the metal surface, the molding conditions and the rheology of the polymer. Additionally, with the aid of design of experiments, AlSi10Mg inserts were produced by laser powder bed fusion (L-PBF), and their surfaces were structured with submillimetrical dimensions features on the metal surface, so-called, inkpot-like, mushroom-like and lattice structures. Afterwards, the metal inserts were hybridized with PC via injection overmolding and the interfacial strength were evaluated. PC/AA6061 and PC/AlSi10Mg joints exhibited outstanding joining strength of 7.2 MPa ± 0.5 MPa and 20.5 MPa ± 3.8 MPa, respectively. Fracture analysis through optical and scanning electron microscopies and digital image correlation (DIC) was used to elucidate the joint failure mechanisms. In dynamic fatigue testing, joints exhibited fatigue life close to 30% ULSF, demonstrating excellent mechanical durability. In addition, PC/AA6061 joints showed excellent hygrothermal stability. The findings add to the comprehension of the manufacturing, mechanical behavior and durability of injection overmolded polymer-metal hybrid structures.Juntas sobrepostas de policarbonato (PC) e ligas de alumínio AA6061 e AlSi10Mg foram fabricadas por sobremoldagem por injeção e avaliadas quanto à estrutura interfacial e o desempenho mecânico. Os parâmetros de moldagem por injeção, temperature do barril, velocidade de injeção e pressão de recalque, foram otimizados a partir de um planejamento de experimentos, utilizando-se insertos de AA6061 usinados a partir de chapa extrudada e texturizados a laser. A força máxima em ensaio de cisalhamento foi utilizada como resposta e os valores correlacionados com o preenchimento do polímero nas cavidades da superfície do metal, as condições de moldagem e a reologia do polímero. Adicionalmente, com auxílio de planejamento de experimentos, insertos de AlSi10Mg foram produzidos e suas superfícies estruturadas por fusão seletiva em leito de pó com estruturas em escalas submilimétricas denominadas tipo tinteiro, cogumelo e treliça. Posteriormente os insertos metálicos foram hibridizados com PC por sobremoldagem por injeção e a resitência interfacial foi avaliado. As juntas PC/AA6061 e PC/AlSi10Mg apresentaram resistências ao cisalhamento notáveis, de até 7,2 MPa ± 0,5 MPa e 20,5 MPa ± 3,8 MPa, respectivamente. Análise de falhas via microscopia ótica e eletrônica de varredura e correlação de imagens digitais (CID) foi empregada para elucidação dos mecanismos de falha das juntas. Em ensaio de fadiga dinâmica as juntas PC/AA6061 e PC/AlSi10Mg apresentaram limite de resistência próximo dos 30% da força máxima de cisalhamento, o que indica excelente durabilidade mecânica. Além disso, juntas PC/AA6061 apresentaram excelente estabilidade higrotérmica. Os resultados contribuem para a compreensão do processo de fabricação, comportamento mecânico e durabilidade de estruturas híbridas polímero-metal sobremoldadas por injeção.Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)164791/2018-388887.569948/2020-002018/24296-0engUniversidade Federal de São CarlosCâmpus São CarlosPrograma de Pós-Graduação em Ciência e Engenharia de Materiais - PPGCEMUFSCarAttribution-NonCommercial-NoDerivs 3.0 Brazilhttp://creativecommons.org/licenses/by-nc-nd/3.0/br/info:eu-repo/semantics/openAccessSobremoldagem por injeçãoEstruturas polímero-metalManufatura aditivaPolicarbonatoAlumínioInjection overmoldingPolymer-metal hybrid structuresAdditive manufacturingPolycarbonateAluminumENGENHARIAS::ENGENHARIA DE MATERIAIS E METALURGICAInjection overmolding of polycarbonate-aluminum alloys hybrid structuresSobremoldagem por injeção de estruturas híbridas de policarbonato e ligas de alumínioSpritzgiessen von hybridstrukturen aus polycarbonatalumium-legierungeninfo:eu-repo/semantics/publishedVersioninfo:eu-repo/semantics/doctoralThesis600600807eefcb-da11-4f31-83b1-a2b0d87838e0reponame:Repositório Institucional da UFSCARinstname:Universidade Federal de São Carlos (UFSCAR)instacron:UFSCARORIGINALGean Henrique Marcatto de Oliveira - Tese .pdfGean Henrique Marcatto de Oliveira - Tese .pdfapplication/pdf7472987https://repositorio.ufscar.br/bitstream/ufscar/18217/1/Gean%20Henrique%20Marcatto%20de%20Oliveira%20-%20Tese%20.pdf62bd5a9a79b529f9bd1e2f4999ed1693MD51CC-LICENSElicense_rdflicense_rdfapplication/rdf+xml; charset=utf-8810https://repositorio.ufscar.br/bitstream/ufscar/18217/2/license_rdff337d95da1fce0a22c77480e5e9a7aecMD52TEXTGean Henrique Marcatto de Oliveira - Tese .pdf.txtGean Henrique Marcatto de Oliveira - Tese .pdf.txtExtracted texttext/plain262305https://repositorio.ufscar.br/bitstream/ufscar/18217/3/Gean%20Henrique%20Marcatto%20de%20Oliveira%20-%20Tese%20.pdf.txt9a7084cb0af7b5647d272df6ec65ba70MD53ufscar/182172024-05-14 17:46:04.027oai:repositorio.ufscar.br:ufscar/18217Repositório InstitucionalPUBhttps://repositorio.ufscar.br/oai/requestopendoar:43222024-05-14T17:46:04Repositório Institucional da UFSCAR - Universidade Federal de São Carlos (UFSCAR)false |
dc.title.eng.fl_str_mv |
Injection overmolding of polycarbonate-aluminum alloys hybrid structures |
dc.title.alternative.por.fl_str_mv |
Sobremoldagem por injeção de estruturas híbridas de policarbonato e ligas de alumínio |
dc.title.alternative.ger.fl_str_mv |
Spritzgiessen von hybridstrukturen aus polycarbonatalumium-legierungen |
title |
Injection overmolding of polycarbonate-aluminum alloys hybrid structures |
spellingShingle |
Injection overmolding of polycarbonate-aluminum alloys hybrid structures Oliveira, Gean Henrique Marcatto de Sobremoldagem por injeção Estruturas polímero-metal Manufatura aditiva Policarbonato Alumínio Injection overmolding Polymer-metal hybrid structures Additive manufacturing Polycarbonate Aluminum ENGENHARIAS::ENGENHARIA DE MATERIAIS E METALURGICA |
title_short |
Injection overmolding of polycarbonate-aluminum alloys hybrid structures |
title_full |
Injection overmolding of polycarbonate-aluminum alloys hybrid structures |
title_fullStr |
Injection overmolding of polycarbonate-aluminum alloys hybrid structures |
title_full_unstemmed |
Injection overmolding of polycarbonate-aluminum alloys hybrid structures |
title_sort |
Injection overmolding of polycarbonate-aluminum alloys hybrid structures |
author |
Oliveira, Gean Henrique Marcatto de |
author_facet |
Oliveira, Gean Henrique Marcatto de |
author_role |
author |
dc.contributor.authorlattes.por.fl_str_mv |
http://lattes.cnpq.br/2892871093566684 |
dc.contributor.authororcid.por.fl_str_mv |
https://orcid.org/0000-0002-4403-3643 |
dc.contributor.advisor1orcid.por.fl_str_mv |
https://orcid.org/0000-0002-4138-005X |
dc.contributor.advisor-co1orcid.por.fl_str_mv |
https://orcid.org/0000-0002-1886-1349 |
dc.contributor.author.fl_str_mv |
Oliveira, Gean Henrique Marcatto de |
dc.contributor.advisor1.fl_str_mv |
Canto, Leonardo Bresciani |
dc.contributor.advisor1Lattes.fl_str_mv |
http://lattes.cnpq.br/7287108960864123 |
dc.contributor.advisor-co1.fl_str_mv |
Amancio-Filho, Sergio Traglia |
dc.contributor.advisor-co1Lattes.fl_str_mv |
http://lattes.cnpq.br/7609614295379921 |
dc.contributor.authorID.fl_str_mv |
3951ebea-00e9-4748-bf28-50d3a03e7bb5 |
contributor_str_mv |
Canto, Leonardo Bresciani Amancio-Filho, Sergio Traglia |
dc.subject.por.fl_str_mv |
Sobremoldagem por injeção Estruturas polímero-metal Manufatura aditiva Policarbonato Alumínio |
topic |
Sobremoldagem por injeção Estruturas polímero-metal Manufatura aditiva Policarbonato Alumínio Injection overmolding Polymer-metal hybrid structures Additive manufacturing Polycarbonate Aluminum ENGENHARIAS::ENGENHARIA DE MATERIAIS E METALURGICA |
dc.subject.eng.fl_str_mv |
Injection overmolding Polymer-metal hybrid structures Additive manufacturing Polycarbonate Aluminum |
dc.subject.cnpq.fl_str_mv |
ENGENHARIAS::ENGENHARIA DE MATERIAIS E METALURGICA |
description |
Overlap joints between polycarbonate (PC) and aluminum alloys AA6061 and AlSi10Mg were manufactured by injection overmolding and evaluated regarding the interfacial structure and mechanical performance. The injection overmolding parameters; barrel temperature, injection speed and holding pressure were optimized through a design of experiments, using AA6061 inserts machined from an rolled sheet and laser surface textured. The injection molding parameters studied showed a positive effect on the filling of the grooves on the metal surface. The ultimate lap-shear force (ULSF) was used as a response and the values correlated to the filling of the polymer into the grooves of the metal surface, the molding conditions and the rheology of the polymer. Additionally, with the aid of design of experiments, AlSi10Mg inserts were produced by laser powder bed fusion (L-PBF), and their surfaces were structured with submillimetrical dimensions features on the metal surface, so-called, inkpot-like, mushroom-like and lattice structures. Afterwards, the metal inserts were hybridized with PC via injection overmolding and the interfacial strength were evaluated. PC/AA6061 and PC/AlSi10Mg joints exhibited outstanding joining strength of 7.2 MPa ± 0.5 MPa and 20.5 MPa ± 3.8 MPa, respectively. Fracture analysis through optical and scanning electron microscopies and digital image correlation (DIC) was used to elucidate the joint failure mechanisms. In dynamic fatigue testing, joints exhibited fatigue life close to 30% ULSF, demonstrating excellent mechanical durability. In addition, PC/AA6061 joints showed excellent hygrothermal stability. The findings add to the comprehension of the manufacturing, mechanical behavior and durability of injection overmolded polymer-metal hybrid structures. |
publishDate |
2023 |
dc.date.accessioned.fl_str_mv |
2023-06-29T16:21:55Z |
dc.date.available.fl_str_mv |
2023-06-29T16:21:55Z |
dc.date.issued.fl_str_mv |
2023-03-24 |
dc.type.status.fl_str_mv |
info:eu-repo/semantics/publishedVersion |
dc.type.driver.fl_str_mv |
info:eu-repo/semantics/doctoralThesis |
format |
doctoralThesis |
status_str |
publishedVersion |
dc.identifier.citation.fl_str_mv |
OLIVEIRA, Gean Henrique Marcatto de. Injection overmolding of polycarbonate-aluminum alloys hybrid structures. 2023. Tese (Doutorado em Ciência e Engenharia de Materiais) – Universidade Federal de São Carlos, São Carlos, 2023. Disponível em: https://repositorio.ufscar.br/handle/ufscar/18217. |
dc.identifier.uri.fl_str_mv |
https://repositorio.ufscar.br/handle/ufscar/18217 |
identifier_str_mv |
OLIVEIRA, Gean Henrique Marcatto de. Injection overmolding of polycarbonate-aluminum alloys hybrid structures. 2023. Tese (Doutorado em Ciência e Engenharia de Materiais) – Universidade Federal de São Carlos, São Carlos, 2023. Disponível em: https://repositorio.ufscar.br/handle/ufscar/18217. |
url |
https://repositorio.ufscar.br/handle/ufscar/18217 |
dc.language.iso.fl_str_mv |
eng |
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eng |
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600 600 |
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807eefcb-da11-4f31-83b1-a2b0d87838e0 |
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Attribution-NonCommercial-NoDerivs 3.0 Brazil http://creativecommons.org/licenses/by-nc-nd/3.0/br/ info:eu-repo/semantics/openAccess |
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Attribution-NonCommercial-NoDerivs 3.0 Brazil http://creativecommons.org/licenses/by-nc-nd/3.0/br/ |
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openAccess |
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Universidade Federal de São Carlos Câmpus São Carlos |
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Programa de Pós-Graduação em Ciência e Engenharia de Materiais - PPGCEM |
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UFSCar |
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Universidade Federal de São Carlos Câmpus São Carlos |
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