Progressive metal-composite laminate
Background
Stalcom Lightweight Laminate (SLL) has been created by Stalcom Automotive, a full-service engineering consultancy working with chosen partners that offer complimentary technologies. Stalcom has been developing new ways of combining light metals such as high strength aluminium and magnesium with a variety of thermoset and thermoplastic composites to optimize strength and rigidity.
The Powderbond Solution
The company recognised the advantages in strength and rigidity that would be provided by an aluminium-glass fibre polypropylene composite laminate, constructed in layers, as a ‘sandwich’. The stumbling point was finding a means of bonding the thermoplastic-based composites to the metal, strongly and reliably.
PowderBond was the perfect solution to this challenge. In a compression moulding process, PowderBond-treated aluminium is sandwiched between layers of pierce resistant GFPP composite (W8SVR® Woven laminate).
A three-year programme of R&D activity at Stalcom, supported by the Niche Vehicle Network and the Advanced Propulsion Centre (TDAP), involved extensive trials to advance the readiness of the technology and confirm the manufacturing processes.
SLL is being sought after in the growing EV market. It is an essential component of the PACES platform. It is also used as aluminium-polypropylene composite structural elements for the chassis of lightweight commercial vehicles.
Benefits
No polypropylene adhesives or aluminium adhesives need to be used.
The SLL hybrid material exploits the best properties of both materials. Aluminium provides emc screening and earth conductivity and affordable polypropylene composite offers puncture resistance and cost efficiency.
For the electric vehicle sector, weight reduction with SLL is typically 20% less than using aluminium alone, whilst impact resistance is greatly improved over same single material thickness.
Recent back-to-back Reg100 fire tests have shown that the internal peak temperature seen by the laminate design is reduced by a minimum of 60 degrees when compared to an aluminium base plate, preventing any significant internal damage.
Find out more
If you would like further information on the benefits that PowderBond could bring to your design please call us for a chat. We will work closely with you through evaluation for your own particular application.
