Various embodiments relate to plastic-metal junctions and methods of making the same via laser-assisted joining. The present invention provides a method of forming a junction between a metal form and a solid plastic. The method can include laser treating a surface of a metal form to generate a feature (e.g., a plurality of at least one of pores and grooves) in the surface of the metal, wherein the laser has an angle of incidence with the surface of the metal of other than 0 degrees. The method can include contacting the metal surface including the feature with a flowable resin composition. The method can include curing the flowable resin composition to form the solid plastic, to provide the junction between the metal form and the solid plastic.

A new ultrasonic aided laser joining method (UAL) for bonding dissimilar materials has been developed. The method is capable of eliminating the laser-induced bubbles at the bonding faces and to improve the joint strength over that of the conventional laser-assisted metal and plastic joining method (LAMP). Some experiments on joining titanium to polyethylene terephthalate have been conducted to show the superiority of UAL over LAMP. The results showed that the joint strength, measured in terms of failure load, was significantly increased when ultrasonic vibration was employed during laser joining. For the LAMP joined specimens, fracture normally occurred at the metal-plastic interface, whereas for the UAL joined specimens, fracture normally occurred in the parent plastic part. The improvement in joint strength is mainly due to the elimination of pores in the resolidified plastic. In addition, ultrasound vibration promotes chemical bonding between the plastic and metal parts, and this is supported by the XPS results.

A structural assembly (900) and method of fabricating the same, the method comprising: providing a first member (204) comprising a bond surface (800) and a plurality of protrusions (802) extending from the bond surface (800), a length of each of the protrusions (802) from the bond surface (800) being less than or equal to 2 mm; providing a second member (202) comprising a fibre-reinforced composite material, the fibre-reinforced composite material comprising a plurality of elongate fibres (902) embedded in a polymer matrix (904); while the polymer matrix (904) is in its plastic state, forcing the second member (202) against the bond surface (800) and the protrusions (802) so as to cause the second member (202) to form onto the bond surface (800) and the protrusions (802); and thereafter causing the polymer matrix (904) to harden, thereby fixing the first member (204) to the bond surface of the second member (202).

The present invention provides polymer-metal composites free of adhesives and methods of making same. In particular, the present invention takes advantage of a unique metallic bonding surface created by exposure to a laser whereby micron-sized fragments are fixed to the metallic bonding surface such that a high strength bond with polymeric material is created upon exposure to a second laser.

A composite component for a motor vehicle includes a first section; and a second section connected to the first section. The first section comprises a metallic material. The second section comprises a plastic. The first section has a first base region and projections provided on the first base region, wherein the projections provided on the first base region extend from the first base region to the second section. The projections provided on the first base region have undercuts, and the projections provided on the first base region are anchored in the second section in order to bring about the connection between the first section and the second section.

Provided are a metal clad laminate and a method for producing the same. The metal clad laminate at least includes a thermoplastic liquid crystal polymer film and a metal sheet bonded to each other, wherein the thermoplastic liquid crystal polymer film has a surface with a glossiness (20) of 55 or higher in accordance with JIS Z 8741 on the opposite side of the bonding surface to the metal sheet. The method for producing a metal clad laminate at least includes: providing a thermoplastic liquid crystal polymer film 2 and a metal sheet 6; and introducing the thermoplastic liquid crystal polymer film 2 and the metal sheet 6 between a pair of heating rolls so as to laminate them.

In a method for producing a rail-shaped hybrid component, in particular for an aircraft or spacecraft, a second rail component made of a titanium material is positioned on a first bar of a first profile rail that is made of a carbon-fiber reinforced plastic material and moved in an advancing direction, in a fixed position relative to the first profile rail, such that a bar portion of the first bar is arranged between a first connecting portion of the second rail component and a second connecting portion of the second rail component, and the second rail component is cohesively connected to the first profile rail. Furthermore, the hybrid component has a first profile rail made of a carbon-fiber reinforced plastic material and a second rail component made of a titanium material.

An attachment component which includes a body, the body having attachment means intended for allowing the attachment component to be assembled with a part including complementary attachment means, an insertion tip arranged at one end of the body so as to allow at least one portion of the body to be inserted through a part made of composite material, an axial abutment intended for halting the insertion of the body through the part made of composite material, and a breakable portion inserted between the insertion tip and said end of the body, the breakable portion being configured to break when a predetermined force is applied to the insertion tip with a view to detaching the insertion tip from the body.

A composite blade includes a composite blade body including reinforced fibers and resin; a metal layer provided on an outer side of a leading edge section including a leading edge that is a part of the composite blade body on an upstream side of an air stream, the metal layer having a thickness of equal to or larger than 5 micrometers and equal to or smaller than 100 micrometers; an adhesive layer provided between the composite blade body and the metal layer to bond the metal layer to the composite blade body; and an electric insulating layer provided in contact with a surface of the leading edge section of the composite blade body, the surface being on the side on which the metal layer is provided, the electric insulating layer having an electric insulating property.

A metal-resin joining method of joining a metal member to a composite material member including a fiber reinforced plastic composite material includes an applying step of applying a first adhesive that is a thermosetting adhesive to a first region between the metal member and the composite material member, and applying a second adhesive that is a thermosetting adhesive to a second region between the metal member and the composite material member, a provisional bonding step of irradiating a first irradiation region of the metal member opposed to the first region with a laser light, and heating and curing the first adhesive to provisionally bond the metal member and the composite material member together, and a main bonding step of curing the second adhesive after the provisional bonding step to bond the metal member and the composite material member together.