Int J Adv Manuf Technol (2016) 86:2119–2126
DOI 10.1007/s00170-015-8259-8
ORIGINAL ARTICLE
Manufacturing polymer/metal macro-composite structure
for vibration damping
Mihrigul Altan 1 & Meral Bayraktar 1 & Burak Yavuz 1
Received: 18 August 2015 / Accepted: 17 December 2015 / Published online: 18 January 2016
# Springer-Verlag London 2016
Abstract Metal/polymer-combined macro-composite struc-
tures are representative of a unique combination to achieve
improved quality of products. In this work, a non-traditional
method for manufacturing metal/polymer-combined sand-
wich structure for vibration damping was generated from a
traditional method, plastic injection molding, which is then
called plastic injection forming (PIF). In the experimental
study, aluminum plates with dimensions for the metal part of
the macro-composite and three different types of polymeric
material were used for the core of the sandwich structure:
polypropylene, nano-titan dioxide-added polypropylene, and
thermoplastic elastomer (TPE). For determining flexural
strength of macro-composite structures, a 3-point bending test
was applied. Finite element analysis by commercial ANSYS
code was utilized to compare the bending results with finite
element method (FEM). Force transmissibility test was per-
formed in order to define damping characteristics of the
macro-composite structures. The damping ratio of each struc-
ture was figured out by performing frequency analysis.
Finally, damping characteristics of these composite structures
were discussed by comparing their damping ratios.
* Mihrigul Altan
meksi@yildiz.edu.tr
Meral Bayraktar
mbarut@yildiz.edu.tr
Burak Yavuz
burakyavuz24@gmail.com
1
Department of Mechanical Engineering, Yıldız Technical University,
34349 Istanbul, Turkey
Keywords Polymer/metal sandwiches . Macro-composite .
Plastic injection molding . Vibration damping
1 Introduction
The usage of hybrid materials provides many advantages by
means of integrating the unique properties of each combined
material. In particular, polymers combined with metals are
used in the automotive and aircraft industries because of their
lightweight nature, strength, and easy-forming process. The
recent trend in developing these kinds of materials is for re-
ducing labor cost and weight without any losses in safety and
functionality [1–4]. However, manufacturing these products is
generally time consuming and is not very practical economi-
cally. These types of products are usually in a sandwich struc-
ture that consists of two thick and high strength skin layers
with a soft core. The adhesion between these layers is provid-
ed with various adhesives. Unfortunately, it becomes difficult
to manufacture a complex geometrical sandwich structure
with good dimensional tolerance when both metal and plastic
components are required to have perfect matching of the outer
surface of the plastic part to the inner surface of the metal part
[2]. At this stage, manufacturing plastic and metal components
separately and then bonding them is not productive due to
high labor costs and insufficient dimensional accuracy.
Polymer injection forming (PIF) is one of the recent methods
in generating polymer/metal sandwich structures having dif-
ferent geometries in one step with high-dimensional accuracy
[5–7]. The main advantage of the PIF process is the ability to
perform this method on a conventional injection molding ma-
chine in one-step production. The PIF process was patented
one decade before [8], but there have been continuous studies
since that time. It is still an attractive process for
2120 Int J Adv Manuf Technol (2016) 86:2119–2126

manufacturers and the researchers who desire to design and Table 1 Properties of
aluminum Properties
produce new polymer/metal hybrid structures.
The principle of the PIF process is based on the injection of Elastic modulus (GPa) 70
molten material into the mold where a metal sheet is placed Tensile strength (MPa) 90
priory. By effect of the pressure of the viscous polymer, the Yield strength (MPa) 35
metal is shaped in the cavity of the mold similar to the punch- Hardness (Brinell) 23
die mechanism. Because the metal sheet is deformed in the Elongation at break (%) 35
mold, it is either drawn, stretched, or both. The adhesion be-
tween the polymer and metal surfaces can be provided with
various methods [1, 9–12]. One method for improving the
suppresses the vibration of the sandwich beams. Nilsson
adhesion between the polymer and metal is the usage of silane
and Nilsson [16] generated a method to predict the modes
[9]. Boerio and Shah used PVC with a silane (γ-amino-pro-
of vibration of the lightweight honeycomb cores with thin
pyl-triethoxy-silane)-coated mild steel sheet [11]. During the
laminates bonded to each side of the core. Hao and Rao
injection molding process, PVC was injected onto the silane-
[17] used viscoelastic-layered systems to provide a simple
coated metal substrates. Successful adhesion results were re-
and flexible solution for damping vibration of sheet metal
ported. To increase adhesion, a micron-sized roughness
panels. They presented an analytical formulation to pre-
should be provided on metal surfaces. For this aim, polishing,
dict the stiffness and damping of three-layered beams with
sandpapering, etching, and anodizing treatments can be ap-
two different viscoelastic materials adjacent to each other.
plied [1, 2]. These applications on metal surfaces will increase
There are also some more recent studies of the vibration
mechanical interlocking in micro-scale but, in some cases,
damping properties of the hybrid materials Yang et al.
macro-scale mechanical locking may be needed. In the study
[18] investigated the vibration and damping performances
of Zoellner and Evans [5], nylon6 was experienced in the PIF
of hybrid carbon fiber composite pyramidal truss sand-
processes, but metal inserts with flared through holes were
wich panels with viscoelastic layers embedded in the face
stamped and placed in an injection mold and these holes be-
sheets being investigated in this paper. They increased the
haved like rivets as the molten polymer penetrated and solid-
damping loss factors of sandwich structures due to the
ified along the holes. This structure is a good example for
viscoelastic layer embedded in the face sheets. Aumjaud
interlocking in macro-scale.
et al. [19] have analyzed the performance of a viscoelastic
The vibration characteristics of sandwich materials
damper for honeycomb sandwich structures by using
have drawn great attention for many years. Especially in
constrained layer dampers. They identified the most effi-
automotive or aircraft industry, materials with high vibra-
cient configurations of constrained layer damper by com-
tion damping ratio are preferred due to the long life of the
paring its efficiency with benchmarked optimal configu-
related tools on the vehicles and due to the comfort of the
rations of constrained layer dampers on beam and plate
passengers. The dynamic parameters of these kinds of
structures. They tried to find which damper and in which
materials such as natural frequency, damping characteris-
configuration gave the highest vibration damping
tic, and mode shapes are determined by some tests such as
property.
impact hammer test or shaker test by applying a known
Although there have been many studies about the vibration
input force to the structure. Although it is known that the
damping properties of the sandwich structures, the general
impact hammer is simple, portable, inexpensive, and
geometry of these structures are in the form of layer-by-layer
much faster to use than a shaker, it is often not capable
processing. In this study, polymer/metal hybrid-structured
of imparting sufficient energy to obtain adequate response
macro-composites were obtained by PIF process. The flexural
signals in the frequency range of interest. Also, it is dif-
properties and vibration damping ability of the PIF parts were
ficult to control the direction of the applied force with an
investigated, which has not been observed before.
impact hammer [13]. Ewins [14] gave detailed informa-
tion about theory and application of vibration test
methods, and also, many researchers have done studies Table 2 Properties of the commercial polymers used in the
on the vibration damping properties of the sandwich experimental study
structures [15–19]. For example, Hwu et al. [15] investi-
gated smart composite sandwich beams with surface- PP TPE
bonded piezoelectric sensors and actuators in order to de- Elastic modulus (GPa) 1–2 0.25
sign a controller. They developed an analytical model, and Melt flow index (g/10 min) 6.2 15
by considering the effects of rotary inertia and shear de- Hardness 68 (shore D) 70 (shore A)
formation, they made it possible to solve forced vibration Elongation at break (%) 25 600
problems by modal analysis. Also, they verified that this
Int J Adv Manuf Technol (2016) 86:2119–2126
Fig. 1 Steps of plastic injection
forming
2 Experimental setup
2.1 Materials and preparation
The metal plates were aluminum (Al-1100) with dimensions
of 115 × 75 × 1.5 (mm). The main polymer material used as a
core material was polypropylene, PP (56M10, Sabic Inc.). A
commercial-grade thermoplastic elastomer (TPE; Thermopol
Inc.) was also used as a core material which included 30 % of
styrene block copolymer within PP. The properties of the com-
mercial materials are given in Tables 1 and 2. Another poly-
meric core used for the hybrid structure was titan dioxide-
added (5 wt.%) polypropylene, which was prepared on a
laboratory-type twin screw extruder with a L/D ratio of 20.
The titan dioxide particles (Nabond Inc.) had an average di-
ameter of 20 nm. The operation temperature on the extruder
was set as 220 °C at the die, and the speed of the screw was
60 rpm. The extrudate strands were granulized for plastic in-
jection molding.
Before the injection molding process, the surfaces of the
metal plates were prepared to provide good adhesion between
the polymer and metal by applying the following steps: scrub-
bing the surfaces with 3 M diapad (HandSanding Sponges-red
series) having Al2O3 particles on it, washing the plates in
baths including alkaline soap, rinsing the plates with distilled
water, then acetone, and finally with distilled water. After
drying the plates, an elastomeric nature primer (EMS 30-35,
Metsan Inc.) including chloride, synthetic elastomer, and resin
Fig. 2 a Three-point bending test setup and b cut specimens from the
sandwich structure
2121
with antioxidants was applied on the surfaces of the metal
plates to provide adhesion between the metal and the polymer.
This type of primer becomes more adhesive with the incre-
ment of the heat and pressure, so it is suitable to use in plastic
injection molding process.
2.2 Characterization of the materials
Melt flow index (MFI; Ceast 7021) test and differential
scanning calorimeter (DSC; Perkin Elmer DSC-7) analy-
sis were applied in order to characterize the core material
of polypropylene/titan dioxide (PP/TiO2). MFI test was
applied at 190 °C with 2.16 kg. DSC analysis was applied
in nitrogen atmosphere. The samples (4–5 mg) were heat-
ed and cooled between 40 and 180 °C at 10 °C/min. Then,
melting temperature (Tm) and crystallization temperature
(Tc) were obtained.
2.3 Plastic injection process
A conventional 40-tonne plastic injection molding ma-
chine (Yelkenciler Inc., Turkey) was used in which the
process was converted into the plastic-forming process
(PIF). As given in Fig. 1, two aluminum plates were
placed in the mold; one was on the moveable mold half,
and the other was on the stationary mold (step 1). When
the hot molten polymer was injected into the mold, the
metal plate placed on the cavity was shaped by the effect
of the injection pressure of the molten polymer and, si-
multaneously, the polymer was filled and solidified be-
tween two aluminum plates (step 2). After ejection, a
formed polymer/metal sandwich structure was obtained
(step 3).
2.4 Bending test
The 3-point bending test was performed using a Universal
Tensile Testing Machine Zwick 1455 in accordance with
ASTM-C393 as shown in Fig. 2a. The bending test specimens
were cut from the macro-composites as given in Fig. 2b. The
speed of the crosshead was 5 mm/min.
2122
Fig. 3 a Experimental setup and
b vibration transmissibility
measurement of the specimen
2.5 Vibration damping test
Force transmissibility method was used to determine the
damping ratio of the specimens. The general arrangement of
transmissibility measurement is shown in Fig. 3a, b.
Bruel&Kjaer (B&K) Type 4808 exciter is used (Fig. 3a) for
excitation of the specimens in order to find out the damping
ratio using vibration transmissibility measurements. The ex-
citer generates accelerations in the range of 10 to 10,000 Hz.
The acceleration applied to polymer/metal sandwich is mea-
sured by B&K Type 8305 (Fig. 3a) standard reference accel-
erometer screw down to B&K WA 0438 adopter (Fig. 3a),
whereas the vibration transmitted by the structure is measured
by B&K Type 4374 (Fig. 3b) acceleration as an output. The
data acquisition process is controlled using a dual-channel
frequency analyzer (B&K Type 2133). The main idea of the
method is to calculate the vibration transmissibility by the rate
of output acceleration to input acceleration.
For a single degree of freedom system (Fig. 4) when the
base of the system is subjected to a harmonic motion, y(t) = Y
sin ωt, the equation of motion is given by Eq. (1):
mz⋅⋅ þ cz⋅ þ kz ¼ −my⋅⋅ ð1Þ
where z denotes the displacement of the mass relative to the
base. Hence, the displacement transmissibility is given by
Eq. (2):
( )1 =
output 1 þ ð2βrÞ2 2
Td ¼ ¼ ð2Þ
input ð1−r2 Þ2 þ ð2βrÞ 2
where β is damping ratio and r is frequency ratio (frequency/
undamped natural frequency). This equation is also equal to
Fig. 4 Single degree of freedom system
Int J Adv Manuf Technol (2016) 86:2119–2126
the ratio of the maximum steady-state accelerations of the
mass and the base [13].
3 Results and discussion
3.1 Characterization of the polymeric materials
The DSC results of the pure PP and titan dioxide-added PP are
given in Fig. 5. Melt temperature and crystallization tempera-
ture of the titan dioxide-added PP did not change apparently in
accordance with pure PP. MFI result of the PP/TiO2 was
5.12 g/10 min, while pure PP had 6.2 g/10 min of MFI value.
It was clear that the presence of inorganic particles increased
the viscosity. All these results were important for setting the
injection parameters for PIF. The little change in melt temper-
ature showed that melt temperature or mold temperature on
injection molding machine could be kept constant for PP and
PP/TiO2, but the decrease in MFI indicated that injection rate
(cm3/s) should be increased as the material was changed from
PP to PP/TiO2.
3.2 Plastic injection forming
Polymer/metal hybrid structures were obtained by PIF process
after determining the ideal injection process conditions. In this
regard, MFI results were taken into account. The greater MFI
values needed smaller injection rate (cm3/s) such as 24 cm3/s
for pure PP, while 28 cm3/s was selected for TPE due to its
higher viscosity. Mold temperature and melt temperature were
taken constant for three polymeric materials as 40 and 240 °C,
respectively. No critical difference was observed in selecting
mold temperate or melt temperature for each of the three poly-
mers because their melting points were close to each other. On
the other hand, injection pressure was significantly effective in
deforming the aluminum plate in the mold so different injec-
tion pressures were experienced between 30 and 60 MPa. As
the injection pressure was increased, the deformability of the
metal plate by PIF increased, but when it was equal to 60 MPa,
tearing was observed along the flange region of the plate dur-
ing deforming due to the excessive pressure application as
shown in Fig. 6. Therefore, after application of serial tests,
45 MPa was found to be the suitable injection pressure for
Int J Adv Manuf Technol (2016) 86:2119–2126
Fig. 5 DSC results of PP and
titan dioxide-added PP
deforming the plate by PIF. After determining the optimal
processing conditions, polymer/metal hybrid structures were
obtained in accordance with the principle given in Fig. 1. The
photograph of a macro-composite specimen and its cross-
section are given in Fig. 7.
3.3 Bending test results
Three different polymeric cores were experienced in PIF pro-
cess, and bending test was applied to determine the flexural
properties of these hybrid structures. The dimension of the
hybrid structure is 115 × 75 × 6 mm (±0.4). In order to obtain
3-point bending test specimens, rectangular specimens
(80 × 10 × 6 mm) were cut along the polymer/metal sandwich
structures by water jet as given in Fig. 2b. The presence of
abrasive water was assumed that it affected the adhesion layer
between metal plates and polymeric core negatively; there-
fore, finite element method (ANSYS Mechanical Apdl
v12.1) was applied to observe the bending results of the
macro-composites with a pure PP core. 3D elements with four
nodes (plane 181) were chosen. On the structural model, five
layers were identified as follows: two metal face sheets, one
polymeric core, and two thin adhesion layers between metal
faces and polymeric core. The density, elastic modulus, and
Poisson’ s ratio of the materials were used. The results are
given in Fig. 8.
The results of the 3-point bending test are given in Fig. 9 as
stress-displacement graphs. When the results of experimental
study and finite element method (FEM) were compared in
Table 3, it can be seen that the application of water jet did
Fig. 6 Deformability of aluminum plate by PIF
2123
not damage the adhesion layer apparently. FEM analysis gave
9.87 mm of deflection at maximum load while the experimen-
tal result gave 9.36 mm. Also, flexural stress obtained from
experimental and FEM are very close to each other, 29.37 and
28.99 MPa, respectively. As a consequence, the 3-point test
was applied to all hybrid structures with different cores after
water jet cutting.
According to the graphs in Fig. 9, in the first stage of the
bending test, load increases proportionally with the deflection,
which is the elastic region. For sandwiches with pure PP and
PP with TiO2 core, linear elastic behavior is observed approx-
imately up to 10–15 MPa stress value. Borsellino et al. [20]
investigated the bending behavior of the polymer–metal sand-
wich structure, which was prepared traditionally by hand with
layer-by-layer adhesion, different from the PIF method. They
used polystyrene core with metal skin layers. The first crack
occurred in the polymeric core while in this study, an apparent
crack was not observed under the applied load. This was due
to the more ductile behavior of polypropylene than that of
polystyrene. The obtained flexural stress about was 20–
30 MPa, and in the present study, it was about 29 MPa.
Beyond this value, stress/strain curve shows nonlinear be-
havior. The failure appearance of the skin layers is observed at
approximately 25–27 MPa. The bending test was set to end at
10 mm of deflection, and fracture was not observed in any of
the specimen as shown on the photographs in Fig. 9. Then, the
three curves could be compared according to deflection ac-
cording to load. The polymer/metal sandwich core with TPE,
which had higher elongation ability due to the presence of the
elastomeric nature material, gave higher deflection at lower
loads while sandwich structures with pure PP and PP/TiO2
showed almost the same character.
Fig. 7 a Polymer/metal macro-composite obtained by PIF. b Cross-
section of the macro-composite with two skin layer and a core
2124
Fig. 8 FEM result of polymer/
metal sandwich structure with
pure PP core. a Deflection result
(mm). b Flexural stress result
(MPa)
(a) Deflection results (mm)
(b) Flexural stress results (MPa)
The result obtained from bending tests and FEM analysis
defines that polymer/metal sandwich structures with formed
metal skins and polymeric cores can be obtained by PIF pro-
cess in one-step manufacturing with a satisfactorily good
adhesion.
3.4 Vibration test results
The developed macro-composites are supposed to be the
initial prototypes for future applications in automotive or
aircraft industries, in which hybrid structures are needed
Fig. 9 Stress-displacement curves of polymer/metal sandwich structures
Int J Adv Manuf Technol (2016) 86:2119–2126
with high geometrical accuracy. In this regard, the vibra-
tion damping property of these products will be probably
improved due to the high geometrical compatibility of
each component; metal and polymer. In the present
study, the generated macro-composites are prepared in
rectangular shape in order to perform standard tests for
investigation.
It should be mentioned that the comparison of the
damping characteristic of the numerous materials is dif-
ficult due to the differences in the testing method and
specimen configuration in the work of different re-
searchers. Also, it should be paid attention that the vi-
bration test has been performed in room temperature. In
fact, Colakoglu [21] has revealed a functional relation-
ship between temperature and the damping factor by pre-
senting the test results of damping ratio for polyethylene
fiber composite beam in the range of −10 to 60 °C.
In this study, as a result of force transmissibility test, the
obtained damping ratios of pure PP, PP/TiO2, and TPE are
presented in Table 4 as 0.12744, 0.060345, and 0.181585,
Table 3 Comparison of FEM and experimental results for polymer/
metal sandwich structure with pure PP core
Flexural stress (MPa) Deflection (mm)
Experimental 29.37 9.87
FEM 28.99 9.36
Int J Adv Manuf Technol (2016) 86:2119–2126
Table 4 Resonance frequency and damping ratio of specimens
Specimen Resonance frequency (Hz) Damping ratio
Pure PP 1730 0.127440
PP/TiO2 8000 0.060345
TPE 5000 0.181585
respectively, by considering the related frequencies. The com-
parison of the measured transmissibility results shows that
addition of TiO2 to pure PP causes a decrease in damping ratio
in the rate of 52.6 %. However, presence of TPE in the core of
the macro-composite yields an increase in damping ratio in the
rate of 42.4 %. This leads to the conclusion that TPE presence
additive increases the effectiveness of damping ratio positive-
ly as against other cores.
Furthermore, when the adhesion layers were investigat-
ed by means of the images taken by stereo-optical micro-
scope (Soif XLB 45-B3) as given in Fig. 10, it can be
seen that PP/TiO2 had difficulties in full contact with the
metal surface.
Particle-filled polymeric core was used in order to in-
vestigate its effect on the vibration damping property of
the macro-composite. Unfortunately, in the PIF process,
TiO2-filled polymers gave poorer results than that of pure
polymers or elastomer-added polymers. The reason of this
is due to the higher viscosity of the PP/TiO2, and this
results in weak adhesion between the metal plate and
molten polymer. Circles given in Fig. 10 identify the re-
gional gaps between metal surface and polymer. It can be
seen that it was more difficult for the molten polymer to
fill the micro-roughness on the metal plate when it be-
came more viscous. This results in regional gaps between
the surfaces of the macro-composite. Since damping co-
efficient of the material depends on the friction of the
surfaces, the gaps between the surfaces had negative ef-
fects on the vibration damping ability of the macro-
composites.
In the present paper, the measurements have been per-
formed in the range of 10 Hz–10 kHz. In the work of Ben
et al. [22], the specimens of carbon fiber/epoxy (CFRP)
and glass fiber/epoxy (GFRP) of dimensions
120 × 30 × 2 mm were tested for damping characteristics
Fig. 10 Images of adhesion
zones of polymer and metal layers
(×45)—1, pure PP; 2, PP/TiO2;
and 3, TPE
2125
in the range of 1–40 kHz. It has been observed from the
results that the transmissibility and damping ratio were
almost similar for the entire range of mode frequencies;
however, CFRP specimen has better transmissibility and
damping ratio in the range of 15 to 26 kHz.
Lesser amount of resin increases the friction between
the carbon fibers in the sandwich core (weakening the
cross-linking between the fibers), which leads to higher
values of damping ratios [23]. However, in the present
study, fiber-included polymeric cores were not applied,
but for future studies with PIF, glass, or carbon fiber-
reinforced polymeric cores can be experienced to improve
vibration damping properties of the final product.
4 Conclusions
In this work, polymer/metal sandwich-structured macro-
composites were obtained with plastic injection forming.
During PIF process, injection pressure and injection rate
were considered as the most critical parameters in
deforming the metal plate according to the injection char-
acteristics of the polymeric core material. Comparison of
FEM results with experimental 3-point bending test
showed that adhesion between plates was satisfactorily
provided during the PIF process. When deflections ob-
tained from the 3-point test were investigated for each
macro-composite, the structure with thermoplastic elasto-
mer core gave about 32 % higher deflection than the
others at lower loads due to the presence of elastomer.
On the other hand, structures with pure PP and PP/TiO2
cores gave almost similar flexural stress about 29 MPa,
while macro-composite with the elastomeric core gave
24 MPa. When vibration damping properties of the
macro-composites were compared, TPE has higher
damping ratio (~0.18) than PP (~0.12) and PP/TiO 2
(~0.06). As a result, plastic injection forming is a prosper-
ous and flexible method for manufacturing polymer/metal
sandwich-structured macro-composites in one step within
the variety of shapes. The flexural and damping properties
of the macro-composite are highly depended on core ma-
terial of the structure. The ability to select different poly-
meric cores increases the attractiveness of the PIF process
in the demand of different fields of usage.
2126
Acknowledgment The authors would like to thank The Scientific and
Technological Research Council of Turkey (TUBITAK) for their support
in the scope of the research project (project no. 113M150).
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