METHOD OF BONDING A PLASTICS BODY TO METAL

Abstract: A method of bonding a plastics body to a metal projectile, includes the steps of machining an annular recess or seat onto a projectile body and cleaning the recess. The next step includes coating the recess with metallic coating applied by a plasma flame spray process. A primer is then coated onto the metallic coated recess, the primer including a polymer disolved in a solvent. After drying the primer, the projectile is heated and a quantity of a polymer plastics material is injection molded into the recess to form the plastics body.

Description: METHOD OF BONDING A PLASTICS BODY TO METAL This invention relates to a method of bonding a plastics body to metal, and is particularly applicable to the bonding of a polymer plastics body to the wall of a projectile Some modern day weapon systems including advanced high explosives incendiary projectiles require thin walls of high strength steel in order to meet system performance requirements. These projectiles also require a shallow annular recess or seat into which a polymer body must be firmly bonded. Bonding a polymer body to a steel projectile so as to survive substantial environmental conditions followed by high stress during actual firing of the projectile has to our knowledge not been successfully achieved before. Among the factors which are involved are the chemical stability of the substrate, the mechanical bonding methods, thermal stresses caused by the environment, and chemical stability of the recess/projectile interface. Various methods have been proposed in the prior art to accomplish the bonding of plastics to metals. None of them have been found successful in high stress severe environment situations such as imposed by thin walled high energy projectiles. U.S. Patent No. 4,092,387 discloses a method of producing a plastics body with a surface coating of a metal, the method including the use of a cellular plastic material with a retarder which inhibits the adhesion until the cellular material has expanded. U.S. Patent No. 4,097,353 discloses a method of forming a porous coating by spraying bond particles onto an electrode surface and impregnating the porous layer with an equeous dispersion of very fine particles. U.S. Patent No. 3,352,955 teaches a method for bonding a polyurethane plastics to a metal surface by coating the metal with a glycidyl polyether. U.S. Patent No. 3,763,298 discloses a method of bonding polyethelyene to a surface of a metal article comprising a plating or coating of lead peroxide. U.S. Patent No. 4,075,392 discloses a nickel based alloy which is coated on a ferrous metal to provide increased resistance to heat and corrosion. U.S. Patent No. 3,961,098 discloses a corrosion coating formed on a metal surface by a plasma spray of heated metallic particles including a filler metal of al uminum and an alloy of aluminum. None of these references directly address the problem of bonding a plastics body to a thin walled steel projectile. According to the present invention, there is provided a method of bonding a body of plastics material to a metal, the method comprising the steps of machining a recess in the metal, cleaning said recess; coating said recess with a metallic coating applied by a plasma flame spray process, priming said metallic coated recess with a primer comprising a polymer disolved in a solvent, and drying said primer to evaporate said solvent; heating said metal having the primed and coated recess; and injection molding a quantity of polymer plastics material into the recess. For a more complete understanding of the invention, reference is hereby made to the drawings in which Figures 1 to 4 are cross-sections of part of a projectile body during treatment steps according to a method of the present invention. As shown in Figure 1, the projectile has an annular recess or seat 12 machined into a steel body 10 of the projectile. For a typical 30 millimeter (mm) projectile, the seat depth is approximately 0.51 mm. After forming, the seat is prepared for the next step by degreasing and grit blasting.. Many metallic products are conventionally vapour degreased to remove surface contamination, machining oils, and handling residues. The seat 12 is grit blasted by conventional means to roughen the substrate steel surface, and during grit blasting, areas beyond the seat are protected by a metal mask. The next step in the present method comprises the coating of the surface of seat 12 with a plasma flame sprayed metallic coating 14, shown in Figure 2. As has been mentioned above, a preferred sprayed metal coating is an alloy having a trade name of Metco P-444 and includes chromium, aluminum, molybdenum, iron and nickel. Convent iently, the projectile or spray is rotated during the spraying operation and the metal coating is sprayed onto the seat in layers of about 0.51 to .127 mm until the desired thickness is achieved. The thickness may range from less than 0.076 mm to more than 0.305 mm but it is preferred that the sprayed metallic coating has a thickness ranging from about 0.127 mm to 0.203 mm. Nickel is a preferred metal for plasma flame spray coating of the projectile annular seat. Another preferred metallic coating is Metco P-444 which is an alloy including chromium, aluminum, molybdenum, iron and nickel. It is desirable that the resulting surface be rough and abrasive, such as at least 500 microinches AA. The next step includes coating the metallic coated seat with a primer comprising a plastics polymer dissolved in a solvent, and drying the primer to evaporate the solvent. As shown in Figure 3, the primer coating 16 is applied directly to the metallic coating 14 in the seat 12 of the projectile wall 10. Prior to priming, the projectile is vapour degreased to remove handling residue and to insure a contaminant free surface. The clean surface is then impregnated by brushing on a liquid primer. In a preferred embodiment, the primer is comprised of about 1 part by weight of a polymer such as polyethersulfone and 3 parts by weight of solvent. The solvent was a mixture by volume of 1 part acetone and 3 parts of 1-methyl-2-pyProlidinone. The amount of solvent may range from 1 part polymer to 5 parts solvent to about 1 part polymer and 1 part solvent, with about 1 part polymer and 3 parts solvent being preferred. Other suitable polymers are polysulfones, polycarbonates, nylon, and other polyamides. The freshly primed seat coating is then allowed to dry. Air drying for an hour or more may be then followed by an oven bake to evaporate the carrier solvents and to flow the primer into the porous metal coating. In a preferred embodiment, the temperature profile of the drying step involves a sequential drying of approximately 1 hour at room temperature, 30 minutes at approximately 162 C, 20 minutes at approximately 20400, and 15 minutes at approximately 28700. At this point in time, the primer solvent has evaporated and the remaining polymer has bonded to and flowed within the porous metal coating. Finally, a plastics layer 18 is injection molded onto the primer 16 and metallic coating 14 in the seat 12 of the projectile 10 as shown in Figure 4. In a preferred embodiment, prior to the molding of the layer 18, the projectile is induction heated to a temperature sufficiently high to melt the remaining polymer primer but not sufficient to vaporize the polymer. Preferably, this temperature may range from about 204 0C to about 3700C and preferably from 30000 to 3300C. The hot projectile is then placed into a mold and the plastics layer 18 is then molded onto the primed metal coated seat. After removal from the mold, the projectile is permitted to stand undisturbed for approximately 24 hours to allow relaxation of the normally -occuring molding stresses within the plastics layer. If desired, the plastics layer, which may be of a polmeric material such as polyethersulfone, may be annealed at a temperature approximating the melting point of the polmeric material; for polyethersulfone, an annealing cycle of 18 hours at approximately 18500 to 2040C may be employed for a period of approximately 18 hours to 2 days. A plurality of projectiles made according to the above method were stored at various temperatures and himidity conditions which were known to be adverse storage conditions. A number of rounds were then fired at conventional velocities without any failures. For example, a 30 millimeter projectile was fired at 1402 metres/second, and several 25 millimeter projectiles were fired at 1585 metres/second and 1615 metres/second with total retention of the rotating band, at temperatures ranging from -54 0C to 740C, thus demonstrating the successful bonding of the plastic to metal:

Claims: CLAIMS 1. A method of bonding a body of plastics material to a metal, the method comprising the steps of machining a recess in the metal, cleaning said recess; coating said recess with a metallic coating applied by a plasma flame spray process, priming said metallic coated recess with a primer comprising a polymer dis olved in a solvent, and drying said primer to evapor ate said solvent; heating said metal having the primed and coated recess; and injection molding a quantity of polymer plastics material into the recess. 2. The method of Claim 1, wherein the plasma flame sprayed metallic coating ranges in thickness from 0.076 mm to 0.305 mm, preferably 0.127 mm to 0.203 mm. 3. The method of Claim 1 or 2, wherein the ratio of poly mer to solvent ranges from 1:5 to 1:1, by weight, pre ferably 1:3. 4. The method of Claim 1, 2 or 3, wherein the metal is heated to a temperature sufficient to melt by not vap orize said primer prior to said molding step. 5. The method of Claim 4, wherein the metal is heated to a temperature in the range from 2040C to 3700C pre ferably in the range 3000C to 3300C. 6. The method of Claim 5, wherein the plastics body is annealed at a temperature of up to 2040C for up to 2 days. 7. A metal and plastics body bonded together by the method of any one of the preceding claims. 8. A projectile having an annular recess and formed by the method of any one of Claims 1 to 6.

Inventors: HARGREAVES, CHARLES R., PRICE, STEPHEN J.
Applicants: HONEYWELL INC.
Application year: 1981
Main classification: B29C45
IPC codes: B05D1, B29C45, B32B15