As part of a UK funded SOLMAC Innovation Program, Powdertech Surface Science has developed a time-saving and innovative approach to bonding composites to metals, as proven by Ariel Motor's Hipercar project.
In this car's monobloc chassis, the fiberbond polypropylene composite is bonded to aluminum without using the binder's Powderbond process.This process takes only one step: along with the polypropylene, the powder coated Of the aluminum into the mold, and the curing cycle and the same standard composite material.
'We are very happy with the results,' said Simon Saunders, founder of Ariel Motor. 'The process was both clean and fast, and the bonding strength far exceeded the current method of using adhesives.'
This is a lean manufacturing process that does not require polymer surface preparation, no activation, energy savings and short curing cycles Typically, a typical chassis consists of hundreds of individual parts that are welded and riveted together By creating aluminum-composite bonds in the mold, the number of components used in the Hipercar chassis was reduced by more than 75%.
'Binding metals and composites in a single step offers great design freedom.' "James Grant, director of Powdertech Surface Science, said," Complex shapes can be molded into composite structures and can include In this project, where the best light materials are used where they are needed most, Powderbond makes it possible today.