Assembly - January 2009 - (Page 18) Assembly Innovations components that have the strength and stiffness of metal, while offering the design flexibility and benefits of highperformance thermoplastics. new hybrid material consisting of a The material, MetaFuse, was develpolymer and a nanocrystalline metal oped by DuPont Engineering Polymers alloy can be used to create lightweight (Wilmington, DE), Integran Technologies Inc. (Pittsburgh), and PowerMetal Technologies Inc. (Carlsbad, CA). MetaFuse is made by depositing a thin layer of highstrength nanocrystalline metal—25 to 200 microns thick—onto a component molded from thermoplastic. The process allows engineers to create components in complex shapes that are stronger than magneSporting goods, such as this fishing reel, are among the sium or aluminum and lightweight components that can be made from a new hybrid just as stiff. The metal material consisting of a polymer and a nanocrystalline metal. has an average grain Photo courtesy DuPont Engineering Polymers Hybrid Material Combines Properties of Metal, Plastic A size of 15 to 100 nanometers, about 1,000 times smaller than conventional metals. Together, the hybrid material is two to three times stronger than typical steels and decorative nickel-chrome. Other metal deposition techniques, such as electroplating and vapor deposition, can’t create structures that are nearly as strong. A unique aspect of the technology is that it places the metal in the optimum location to increase stiffness. For bending loads, the placement of the nanometal coating is most beneficial at the outermost edges of the part, furthest from the neutral axis. This is where the maximum tensile and compressive stresses are experienced by a part. The bending stiffness, torsional stiffness and strength of the part all increase. The outer sections experience the largest loads, and this is where the nanometal is most beneficial. The process reduces creep in plastic parts at elevated temperatures; adds a wear-resistant and potentially 18 ASSEMBLY / January 2009 www.assemblymag.com http://robots.epson.com/gvision.htm http://robots.epson.com/gvision.htm http://www.assemblymag.com
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