A welded joint between at least one metal material element and at least one thermoplastic material element is obtained by pressing the elements against each other while applying heat. Contact surfaces of the metal material, which are in contact with the thermoplastic material, are provided with uneven surface portions having a distribution of asperities. With heat applied, the thermoplastic material fills spaces between these asperities and maintains this configuration after subsequent cooling, thereby improving strength of the joint. The uneven surface portions are obtained in a preliminary forming step of the metal material in a press mold, which is configured with a forming surface for generating the uneven surface portions by mechanical deformation and/or with a device for guiding a laser or electron beam. By this technique, hybrid components are obtained made of one or more elements of metal material between which a shaped component of thermoplastic material is interposed.

A bonding structure includes: a plurality of carbon nanotubes; a first bonded member, and a first metal sintered compact bonding first end portions of the plurality of carbon nanotubes and the first bonded member, wherein the first metal sintered compact enters spaces between the first end portions of the plurality of carbon nanotubes, and bonds to the plurality of carbon nanotubes while covering side faces and end faces of the first end portions of the plurality of carbon nanotubes.

A method of attaching a thermoplastic-based workpiece and a metal workpiece involves the use of a metal reaction coating. The metal reaction coating is applied over a base metal substrate of the metal workpiece such that the metal reaction coating faces and contacts the thermoplastic-based workpiece when the two workpieces are assembled in overlapping fashion. To attach the workpieces at their faying interface, an energy source such as, for example, a laser beam or an electric arc, is directed against the metal workpiece to create a zone of concentrated heat that at least warms up the metal reaction coating and melts a portion of the thermoplastic-based workpiece. Such heated activity at the faying interface promotes interfacial chemical bonding between the thermoplastic-based workpiece and the metal workpiece that contributes to an enhanced attachment between the workpieces.

The present invention is generally directed to prepreg composites, typically in the form of unidirectional tapes, which contain at least one reinforcing fiber and a thermoplastic polyester matrix. The prepreg composites can be thermally bonded to a wood-containing material in order to improve the structural performance of the material without requiring adhesives. The prepreg composite of the present invention can be applied to a wide range of wood substrates, including various hardwoods, softwoods, and engineered wood composites.

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.

A multi-material assembly is provided, as well as methods of making a multi-material assembly. The multi-material assembly includes a first coated structural component and a second structural component. The first coated structural component includes a first uncoated portion, and an adhesive is positioned between the second structural component and the first uncoated portion that secures the first coated structural component to the second structural component.

Methods of making a composite structure comprise compression molding a fiber reinforced, thermoplastic component having a web and at least one flange integral with the web; laying up a fiber reinforced, thermoplastic cap; placing the fiber reinforced, thermoplastic cap on the flange; and joining the fiber reinforced, thermoplastic cap with the flange.

A laser welded structure is formed by laser welding together a resin molded body formed from a thermoplastic polymer alloy containing a crystalline resin and an amorphous resin and a metal body made of a metal. A glass transition temperature of the amorphous resin is lower than a melting start temperature of the crystalline resin.

The invention provides a carbon fiber reinforced plastic electrofusion fitting and a self-monitoring method of strain for the fitting. Carbon fiber filled polymer is used to fabricate the fitting to improve the mechanical strength of the fitting. The fitting comprises an electrofusion fitting body embedded with a resistance heating wire and two terminals arranged on the electrofusion fitting body and connected to the two ends of the resistance heating wire respectively. For the self-monitoring of strain, at least one pair of electrodes are set on the surface of the electrofusion fitting. The resistance change between electrodes caused by fitting deformation due to temperature change or mechanical loading during operation can be measured, and could be further used for structural health monitoring of the electrofusion fitting. The combination of mechanical enhancement and strain sensing of the electrofusion fitting can improve the performance and reliability of plastic pipelines.

Presented are repair systems for fixing filler-reinforced polymer structures, methods for making/using such repair systems, and techniques for repairing surface damage/defects of multidimensional fiber-reinforced polymer (FRP) panels. A repair system for fixing a contoured surface of an FRP structure includes a flexible contact sheet that is fabricated from a thermally stable polymer, and has a textured contact surface that seats on the FRP structure and overlays the damaged area. A rigid cover sheet, which may be fabricated from a metal material, a polymeric material, and/or resin-impregnated fiber, has a complementary surface that conforms to the contoured surface of the FRP structure and covers the flexible contact sheet. The repair system also includes a heating element that lays against the rigid cover sheet and applies heat to the contoured surface with a substantially uniform profile that is sufficient to soften/melt portions of the FRP structure neighboring the damaged area.