Development of micro‐form‐fitted amorphous thermoplast/light metal hybrid components

Abstract In order to meet the high demands on tolerances and surface qualities, for example in automotive lighting applications, a hybrid part composed of a light metal (aluminium) and an amorphous thermoplastic (polycarbonate) could be an alternative to the established mono‐materials used today. Due to the lack of adhesion promoter systems for joining this specific material combination, a micro‐form‐fitted connection by creating undercut microstructures by laser ablation is used to achieve a full‐surface bond. First investigations are carried out to ensure the filling of these microstructures with different polycarbonate moulding compounds by over moulding in the injection moulding process. Subsequently, the influence of the moulding compound, the structure arrangement and the influence of a pickling treatment on the bond strength are analysed by tensile shear testing.