Bonding of mixed material structures in the automotive industry

Bonding composite thermoplastics and aluminium without the need for structural adhesives

‘PB Apps’ (PowderBond Applications)’, was funded by the Niche Vehicle Network, under APC UK(Advanced Propulsion Centre UK), in collaboration with Stalcom Automotive Technologies Ltd.

Proof of PowderBond concept by testing across a variety of structural joint configurations

Powdertech’s PowderBond system creates very strong bonds between metal and polypropylene or other plastics with no need for adhesives or composite surface treatment.

Combining composite thermoplastics with aluminium in hybrid material structures, delivers significant cost, weight and environmental benefits, but the process needs new joining techniques.

Previously the patented PowderBond process was developed and showed its potential for application in vehicle structure systems.

PowderBond in vehicle structural joints

PB Apps will prove the performance of PowderBond in a variety of vehicle structural joint configurations, at the extreme automotive environmental conditions.

The project will output a large variety of data with sample joints that will inform design engineers and customers and allow them to adopt this process and consequently this type of lightweight construction. A demonstration eco-vehicle structure will be produced, the chassis of which was recently exhibited at Cenex 2019, shown below.

Data to be collected

PB Apps will further test the PowderBond technology, in particular:

• Joint configurations and geometry

• Joint strength and characterisation 

  • Ambient as built

  • At automotive temperature service range

  • After accelerated environmental exposur

• Moulding and assembly techniques 

This project moves the PowderBond joining technique closer to adoption in structural applications. Its game-changing joint strength was a development from the previous SOLMAC Project.

Project partners:

Niche Vehicle Network, Stalcom Automotive Technologies