SEP 2018


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SEPTEMBER 2018 36 CompositesWorld WORK IN PROGRESS to start increasing the mechanical perfor- mance of plastic-metal hybrids was to find a way to apply the technology to hollow beams or tubes with round or rectangular cross-sections," adds Aiello. e challenge, as always, was to achieve a high-strength bond between the metallic substructure and any composite functional component that was over- molded onto it — a feature particularly important for structure-critical compo- nents like cross-car beams. Initially, the team worked on a technology that was suitable for overmolding standard tubes without the need for special equip- ment. e question became how to selectively deform the tube — create dimples or depressions — in the injec- tion molding machine that would ensure a good interlock between the metal tube and the matrix, and thus achieve high bond strength between the metallic substructure and overmolded composite without causing the tube to collapse at the high pressures typically seen during the molding cycle. After much study, the same LANXESS team that initially devel- oped PMH technology also developed the HPH process. Basically, HPH uses high-flow, highly glass-reinforced PA 6 "structural elements" — injection molded solid tubes with specially designed ribs/fins projecting off the outside — that are placed into the hollow center of a steel or aluminum tube that is, in turn, inserted into an injection molding machine and overmolded with additional GR-PA 6 composite to form external bracketry and other functional components. e structural elements — which are inserted into a tube before that tube is placed into the press for overmolding — prevent tube collapse during molding and help shape/deform the tube via a process called beading or dimpling, during the high-pressure molding process, thereby Read this article online | short. For applications that demand precise temperature control, Mokon offers a full line of heating of heating and cooling systems from -20°F to 700°F (-29°C to 371°C). Download our whitepaper at to learn more. Maximim Flexibility. Maximum Control. 9001:2015

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