Overmoulding of Additively Manufactured Titanium Inserts Using Polyoxymethylene (POM)—Evaluation of Bond Quality as a Function of Process Parameters

Due to their process-induced porous surfaces, additively manufactured structures are not optimized for applications in which friction is a key factor. To improve the frictional properties of additively manufactured titanium inserts of various thicknesses, two tribologically optimized POM materials, which differ in terms of filler composition and contents, were used to overmould the inserts. The titanium inserts were manufactured in two different building directions, resulting in a variation in surface roughness. The main challenge with respect to overmoulding is to maintain an even, thin plastic layer on the titanium insert. In order to evaluate the adhesion between plastic and metal, the interface is examined by optical microscopy and assessment of the peeling resistance. The peeling test shows that the overmoulded titanium inserts with a higher surface roughness are characterized by a higher peeling resistance. It is further revealed that the POM material with a special filler concept shows superior peeling resistance.