Development of a Metal-Based Lightweight Approach Consisting of Cold-Formable Magnesium Sheets in Combination with a Multi-Purpose Powder Coating System

This paper will give an overview about the development of a material system, which consists of a novel formable magnesium alloy that is provided with an effective corrosion protection coating. The corrosion protection is to be realized in the form of a forming stable powder coating, which can be applied in the coil coating process. To improve the tribological properties, additional additives are added to the powder coating. Within this paper, first results concerning tribological and forming behavior of the new lightweight material system are given. For the benchmark, the results are compared with commercially available AZ31 Mg alloy

Basic material and technology investigations for material bonded hybrids by continuous hybrid profile fabrication

The development of multi-material hybrids by injection molding has been studied very intensively at the IPF in the past. For that, a material bonding between the different substrates was achieved by using a newly developed two-step curing powder coating material as latent reactive adhesive. The aim of the project “Hybrid Pultrusion” was to perform a novel approach for the fabrication of material bonded metal-plastic joints (profiles) in a modified pultrusion process. Therefore, powder pre-coated steel coil is combined with a glass-fiber reinforced epoxy resin matrix. For initial basic studies, the impregnated fiber material has been applied on the pre-coated steel sheets using the Resin Transfer Molding process (RTM-process). It was proved via lap shear tests, that this procedure resulted in very high adhesive strengths up to 35 MPa resulting from the formation of a covalent matrix-steel bonding as well. In addition, the failure mechanism was subsequently studied. Furthermore, by adapting the successful material combination to the pultrusion process it was demonstrated that material bonded hybrids can be achieved even under these continuous processing conditions

Chemical Bonded PA66-PTFE-Oil Composites as Novel Tribologically Effective Materials: Part 2

Polytetrafluoroethylene (PTFE) exhibits excellent non-stick properties and a very low coefficient of friction under tribological stress, but it is incompatible with almost all other polymers. In the first part of this study we presented the generation of the novel tribological material based on unsaturated oil, radiation-modified PTFE (MP1100) and Polyamide 66 (PA66). To get a better understanding of the chemical properties and chemical composition of the compounds, the PA66-MP1100-oil-cb (chemical bonded) compounds were examined by differential scanning calorimetry (DSC) and thermal gravimetric analysis (TGA). In this part, the mechanical properties of the compounds are compared with plain PA66 and PA66-MP1100-cb. The tribological investigation was carried out using the Block-on-Ring tribometer. It was found that the mechanical properties of PA66-MP1100-oil-cb with 20 wt.% MP1100-oil-cb only show slight differences compared to PA66, but the tribological properties of the compounds have been significantly improved through chemical coupling between the three components. Finally, the amount of the compound that was deposited on the surface of the steel disc counterpart was analyzed after the tribological testing

Abschlussbericht zum Verbundprojekt: Innovative Technologie zur effizienten Beschichtung faserverstärkter Kunststoffe (SMC) : Teil A: Arbeitspaket: Charakterisierung der Lackierbarkeit von SMC-Materialien durch physikalisch-chemische, mikroskopische und spektroskopische Methoden, Verbesserung der elektrischen Leitfähigkeit von SMC-Materialien

[no abstract available

Stratifizierende Beschichtungen

An urgent need for new smart stratifying powder coating systems, which combine in a cost efficient way high durability and a good performance, with effective protective properties, exists. In the presented study, an innovative concept for smart coatings is proposed, which is based on stratification effects in epoxy and polyurethane components containing powder coating formulations

Smart stratifying powder coatings

Multilayer coatings are state of the art for today's high quality automotive and industrial protective coatings systems. As many as three separate layers are nowadays used for the corrosion protection and optical properties of metals. Additionally, the general trend in the coating industry can be described by the replacement of thick multilayer coatings with thinner, less layer containing and highly efficient coating systems. Because of their UV and weathering stability, polymers on the base of acrylics or polyurethanes must be used as top or clear coats. In principle, these coating layers can be used as liquid or powder coating systems. In addition to the fact that the coatings can be used in a high-performance coating, they can also be used in a high-performance coating performance is observed. One wants to be one of the most cost-effective, one-to-one, and one-to-one-to-one solutions for the future future coating industry. It is obvious, that there is an urgent need for new smart powder coating systems, which combines in a cost efficient way high performance, with effective protective properties, exists. In the presented study, an innovative concept for smart coatings is proposed, which is based on stratification effects in epoxy and polyurethane components containing powder coating formulations

Umformstabile Pulverbeschichtung auf Aluminium Wetterstabile Niedrigtemperatur-Pulverlacke als Grundlage für eine innovative technologische Linie

Im Rahmen eines interdisziplinären BMBF-Verbundvorhabens (BMBF 01 RV 0163) wurden hochflexible, wetterstabile Pulverlacke auf Basis emissionsfreier Uretdionhärter entwickelt, die bei Einbrenntemperaturen zwischen 120 und 150°C zu einem Allophanatnetzwerk aushärten. Mit diesen Pulvern vorbeschichtete Aluminiumbleche lassen sich über komplexe Umformoperationen, wie z. B. Tiefziehen oder Innenhochdruckblechumformung (IHB), in ein 3D-Bauteil umformen. In Realteilversuchen mit Serienwerkzeugen wurde zudem nachgewiesen, dass künftig eine grundlegende und effiziente Umgestaltung des Herstellungsprozesses von Pulverlack-beschichteten 3-D-Aluminiumbauteilen weg von der Stückbeschichtung hin zur Platinenbeschichtung möglich ist

Multi-functional powder coating materials for material bonding in metal-plastic joints: Presentation held at Conference "Modern Materials and Manufacturing", 23-26 April 2019, Tallinn

Caused by the demands of lowering the fuel consumption the transportation industry enhances their efforts of weight-reduction. For that reason a multi-material design and the use of polymeric and polymeric fiber reinforced structures become more and more important. The steadily increasing use of these materials in combination with metal parts made it necessary to change the joining technologies from mechanical joining to adhesive joining. Therefore a further technology step is needed whereas the glue is applied, followed by the assembling. Our goal was to develop powder coating materials with an additional latent adhesive function which not only act as corrosion protection for the metal and for the optical appearance but also comprise a latent reactive adhesive function which can be used to generate metal-plastic joints via highly efficient production chains