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Friction press joining is an innovative joining process for the production of plastic-metal joints without additives, in an overlap configuration. In order to achieve a high bond strength, the metallic joining partner is pretreated with laser radiation. Subsequently, heat is induced by friction and pressure during the joining process, causing the thermoplastic material to melt and adhere to the metallic joining partner. In this work, the temperature distribution during the process in the composite is analyzed and characterized. It was found that the occurring temperatures and temperature differences are not only dependent on the rotational speed, but also on the feed rate. It is also shown that the friction surface temperature can be used as an indirect control variable for a model-based, closed-loop control. Based on these findings, various surface modifications forthe metallic joining partner were investigated and analyzed with regard to the maximum strength of the joint. It was observed that the highest tensile shear strength can be achieved with a quasi-chaotic nano structure. In addition, the joining compound was characterized by a thin section, facilitating the identification of specific zones in the joint. These investigations show the high potential for friction press joining of plastics and metals, and form the basis for a model-based control of the joining zone temperature.

Influence of the laser-based surface modification on the bond strength for friction press joining of aluminum and polyethylene