Computational feasibility analysis of direct-adhesion polymer-to-metal hybrid technology for load-bearing body-in-white structural components

The potential of direct-adhesion polymer metal hybrid (PMH) technology for use in load-bearing structural automotive components is explored computationally. Multi-disciplinary computations are carried out ranging from computational fluid mechanics of injection-mold filling and packing processes, flow-induced fiber orientation analysis, visco-elastic analysis of in-cavity residual stress developments and structural-mechanics computation of injection-molded part warping (under the effect of residual stresses) and deflection under simulated thermal loading encountered in the paint shop and under mechanical in-service loading. The results obtained helped identify the minimum level of polymer-to-metal adhesive strength and an optimal PMH-component architecture which are required in order for the direct-adhesion PMH technology to be considered a viable (weight-saving, parts-consolidation, manufacturing process-chain compatible) alternative to the currently used PMH technologies.