The use of hybrid components is established in the area of lightweight construction in the automotive, aerospace and shipbuilding industry. The advantage of the combination of metal and plastic parts is to reduce the total weight and to generate desired properties which can not be realised with a single bulk material. The production of a hybrid composite structure is often a two-stage process. The first step is the manufacturing of single parts and the second step is the in-mould or post-mould assembly of two or more parts. Correspondingly, a two-stage process is labour-intensive and time-consuming in contrast to a single-stage process.
In this work the implementation of the connection of metal and plastic parts in a single-stage process with the injection moulding process is analysed. Injection moulding is an established industrial process to produce plastic parts and ideal for implementing a hybrid concept. To define the technical process limits, different materials are produced in several test series with varying manufacturing parameters. To evaluate the influence of the manufacturing parameters, samples of the hybrid are analysed with optical methods and the shear edge test. It is shown that the temperature and pressure parameters have the most influence on the connection between metal and plastic parts.