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

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

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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

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

Einbaufertige Hybridbauteile

Im Rahmen des europäische Gemeinschaftsforschungsprojektes beschäftigt sich das Projektkonsortium bestehend aus dem Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU zusammen mit dem Leibniz-Institut für Polymerforschung Dresden e.V. (IPF) und den belgischen Partnern „Centre for Research in Metallurgy“ (CRM) und dem kollektiven Zentrum der belgischen technologischen Industrie Sirris mit der Entwicklung von Technologien und Prozessrouten, welche es ermöglichen Hybridbauteile schneller und effizienter produzieren zu können. Dabei liegt der innovative Ansatz des Projektes in den Bindeschichten zwischen der metallischen Komponente und dem Kunststoff begründet. Durch den Einsatz einer umformstabilen, funktionalisierten 2-in-1-Pulverlackformulierung, welche neben der Funktion der Oberflächenveredelung auch eine latent haftvermittelnde Funktion besitzt, wird die stoffschlüssige Verbindung des Hybridbauteils während des Spritzgießprozesses hergestellt. Auf diese Weise können Thermoplaste kostengünstig auf das entsprechend vorbeschichtete Metall aufgebracht werden mit dem Resultat eines Hybrid-Verbundes, der eine ausgezeichnete Verbundfestigkeit aufweist. Durch den Entfall kostenintensiver Vorbehandlungsschritte kann die Prozesskette verkürzt und somit Kosten eingespart werden

Prefinished metal polymer hybrid parts

In this study, the shaping and assembly behavior of adhesive polymer-metal-composites was investigated in an international cooperation using two step curable uretdione-polyester-based powder coatings (IPF development [1,2]) which acts simultaneously as a reactive adhesive agent and as a high quality surface finish. To create the composite, a thermoplastic polyurethane (TPU) layer with good compatibility to the powder coating was over-molded onto a powder coated aluminum substrate. A polyamide (PA6) layer was over-molded on to the TPU layer to create a stiff composite structure with possibilities for further functionalization. The TPU-layer in between the metal substrate and the polymer top layer acts as a stress and strain compensation layer. These loads are caused by thermal expansion (under fluctuating temperatures) and external forces/deformation. Another key feature of the composite is the innovative process chain. The powder coating can resist high deformation and therefore the coating is suitable for a future application on to a metal substrate using a coil coating procedure. In addition, the coil could be easily implemented into a production line as a semi-finished product. The prefinished coated metal substrate could be formed (e.g. incremental forming, deep drawing) and inserted in the over-molding procedure. This overall shortened process chain allows not only an effective fabrication of pre-coated semi-finished materials and polymer-metal-joints in high quantities by saving process steps (e.g. cleaning steps, glue application) but also a higher versatility in the following composite production

Powder coil coating: With innovative processes towards new products and surfaces

Die Kombination aus einem neuen pistolenlosen Pulverbeschichtungsverfahren und Hochleistungs-Infrarotstrahlern ermöglicht bisher nicht mögliche schnelle Pulverapplikations- und Einbrennprozesse. Dies erlaubt die Pulverbeschichtung von Coils mit Geschwindigkeiten von über 1 m/s sowie die Gestaltung extrem kompakter Pulverapplikations- und Einbrennzonen. In Verbindung mit neuentwickelten hochumformstabilen Niedertemperatur-Pulverlackmaterialien eröffnen sich damit neue Märkte für pulverbeschichtetes Coil. Vorgestellt werden Beispiele aus dem Automobil- und Baubereich