Polymer–Metal Hybrid Material with an Ultra-High Interface Strength Based on Mechanical Interlocking via Nanopores Produced by Electrochemistry

Investigating the Feasibility and Performance of Hybrid Overmolded UHMWPE 3D-Printed PEEK Structural Composites for Orthopedic Implant Applications: A Pilot Study

Ultra-high-molecular-weight polyethylene (UHMWPE) components for orthopedic implants have historically been integrated into metal backings by direct-compression molding (DCM). However, metal backings are costly, stiffer than cortical bone, and may be associated with medical imaging distortion and metal release. Hybrid-manufactured DCM UHMWPE overmolded additively manufactured polyetheretherketone (PEEK) structural components could offer an alternative solution, but are yet to be explored. In this study, five different porous topologies (grid, triangular, honeycomb, octahedral, and gyroid) and three surface feature sizes (low, medium, and high) were implemented into the top surface of digital cylindrical specimens prior to being 3D printed in PEEK and then overmolded with UHMWPE. Separation forces were recorded as 1.97-3.86 kN, therefore matching and bettering the historical industry values (2-3 kN) recorded for DCM UHMWPE metal components. Infill topology affected failure mechanism (Type 1 or 2) and obtained separation forces, with shapes having greater sidewall numbers (honeycomb-60%) and interconnectivity (gyroid-30%) through their builds, tolerating higher transmitted forces. Surface feature size also had an impact on applied load, whereby those with low infill-%s generally recorded lower levels of performance vs. medium and high infill strategies. These preliminary findings suggest that hybrid-manufactured structural composites could replace metal backings and produce orthopedic implants with high-performing polymer-polymer interfaces.

Interface Wetting Driven by Laplace Pressure on Multiscale Topographies and Its Application to Performance Enhancement of Metal-Composite Hybrid Structure

Surface topography reconstruction is extensively used to address the issue of weak bonding at the polymer-metal interface of metal-composite hybrid structure, while enhancement from this approach is seriously impaired by insufficient interface wetting. In this study, the wetting behavior of polymer on aluminum surfaces with multiscale topographies was theoretically and experimentally investigated to realize stable and complete wetting. Geometric dimensions of multiscale surface topographies have a notable impact on interfacial forces at the three-phase contact line of polymer/air/aluminum, and a competition exists between Laplace pressure and bubble pressure in dominating the wetting behavior. Laplace pressure facilitates the degassing of trapped air bubbles in grooves, bringing more robust interfacial wettability to grooves than dimples and grids. Conversely, dimples with excessive dimensions generate interfacial pores, and this intrinsic mechanism is theoretically unraveled. Moreover, different degrees of interface wetting cause variations in bonding strength of polymer-aluminum interface, which changes from ∼18% improvement to ∼17% reduction compared to original strength. Finally, groove topography perfectly achieved complete wetting between polymer and aluminum and consequently improved flexure performance by over 11% for the aluminum-carbon fiber hybrid side impact bar, which verifies the importance of complete wetting at a part scale. This study deepens the understanding of wetting behavior and clarifies the intrinsic correlation between interfacial bonding performance and surface topography.

Modification of Polyamide 66 for a Media-Tight Hybrid Composite with Aluminum

Metal-plastic composites are becoming increasingly important in lightweight construction. As a combination, e.g., for transmission housings in automobiles, composites made of die-cast aluminum housings and Polyamide 66 are a promising material. The interface between metal and plastic and the properties of the plastic component play an important role with regard to media tightness against transmission oil. The mechanical properties of the plastic can be matched to aluminum by glass fibers and additives. In the case of fiber-reinforced plastics, the mechanical properties depend on the fiber length and their orientation. These structural properties were investigated using computer tomography and dynamic image analysis. In addition to the mechanical properties, the thermal expansion coefficient was also investigated since a strongly different coefficient of the joining partners leads to stresses in the interface. Polyamide 66 was processed with 30 wt% glass fibers to align the mechanical and thermal expansion properties to those of aluminum. In contrast to the reinforcement additives, an impact modifier to improve the toughness of the composite, and/or a calcium stearate to exert influence on the rheological behavior of the composite, were used. The combination of the glass fibers with calcium stearate in Polyamide 66 led to high stiffnesses (11,500 MPa) and strengths (200 MPa), which were closest to those of aluminum. The coefficient of thermal expansion was found to be 6.6 × 10^-6/K for the combination of Polyamide 66 with 30 wt% glass fiber and shows a low expansion exponent compared to neat Polamid 66. It was detected that the use of an impact modifier led to less orientated fibers along the injection direction, which resulted in lower modulus and strength in terms of mechanical properties.

Adhesion Engineering in Polymer-Metal Comolded Joints with Biomimetic Polydopamine

Joints that connect thermoplastic polymer matrices (TPMs) and metals, which are obtained by comolding, are of growing importance in numerous applications. The overall performance of these constructs is strongly impacted by the TPM-metal interfacial strength, which can be tuned by tailoring the surface chemistry of the metal prior to the comolding process. In the present work, a model TPM-metal system consisting of poly(methyl methacrylate) (PMMA) and titanium is used to prepare comolded joints. The interfacial adhesion is quantified by wire pullout experiments. Pullout tests prior to and following surface modification are performed and analyzed. Unmodified wires show poor interfacial strength, with a work of adhesion (Ga) value of 3.8 J m-2. To enhance interfacial adhesion, a biomimetic polydopamine (PDA) layer is first deposited on titanium followed by a second layer of a poly(methyl methacrylate-co-methacrylic acid) (P(MMA-co-MAA)) copolymer prior to comolding. During processing, the MAA moieties of the copolymer thermally react with PDA, forming amide bonds, while MMA promotes the formation of secondary bonds and molecular interdigitation with the PMMA matrix. Control testing reveals that neither PDA nor the copolymer provides a substantial increase in adhesion. However, when used in combination, a significant increase in adhesion is detected. This observation indicates a pronounced synergistic effect between the two layers that strengthens the PMMA-titanium bonding. Enhanced adhesion is optimized by tuning the MMA-to-MAA ratio of the copolymer, which shows a maximum at a 24% MAA content and a greatly increased Ga value of 155 J m-2; this value corresponds to a 40-fold increase. Further growth in the Ga values at higher MAA contents is hindered by the thermal cross-linking of MAA; MAA contents above 24% restrict the formation of secondary bonds and molecular interdigitation with the PMMA chains. Our results provide new design principles to produce thermoplastic-metal comolded joints with strong interfaces.