System for joining dissimilar materials

A method of joining dissimilar materials, comprising:

• (a) laser etching a predetermined micropattern into a surface of a first material, wherein the first material is a metal used for creating a part, and wherein the micropattern includes various microfeatures;
• (b) characterizing the physical properties of the microfeatures;
• (c) characterizing a second material, wherein the second material is a solid polymer used for creating a part, and wherein the characterization of the second material includes:
• (i) measuring a degradation temperature of the polymer;
• and
• (ii) measuring a melting point/critical flow temperature of the polymer;
• (d) placing the polymer on the microfeatures formed on the metal surface to form an interface between the polymer and the metal and to form a polymer-metal combination;
• (e) applying a predetermined amount of compressive force to the polymer-metal combination;
• (f) for a predetermined period of time, heating the interface to a temperature falling between the degradation temperature of the polymer and the melting point/critical flow temperature of the polymer;
• (g) discontinuing heating the interface;
• (h) continuing to apply the compressive force to the polymer-metal combination until the interface between the polymer and the metal has solidified and the materials have been joined;
• and
• (i) discontinuing application of the compressive force.

A method for joining dissimilar materials, comprising:

• (a) laser etching a predetermined micropattern into a surface of a first material, wherein the first material is a metal used for creating a part, and wherein the micropattern includes various microfeatures;
• (b) characterizing the physical properties of the microfeatures;
• (c) characterizing a second material, wherein the second material is a solid polymer used for creating a part, and wherein the characterization of the second material includes:
• (i) measuring a degradation temperature of the polymer using thermogravimetric analysis;
• and
• (ii) measuring a melting point/critical flow temperature of the polymer using differential scanning calorimetry;
• (d) placing the polymer on the microfeatures formed on the metal surface to form an interface between the polymer and the metal and to form a polymer-metal combination;
• (e) applying a predetermined amount of compressive force to the polymer-metal combination;
• (f) for a predetermined period of time, heating the interface to a temperature falling between the degradation temperature of the polymer and the melting point/critical flow temperature of the polymer;
• (g) discontinuing heating the interface;
• (h) continuing to apply the compressive force to the polymer-metal combination until the interface between the polymer and the metal has solidified and the materials have been joined;
• and
• (i) discontinuing application of the compressive force.

A method for joining dissimilar materials, comprising:

• (a) etching a predetermined micropattern into a surface of a first material, wherein the first material is a metal used for creating a part, and wherein the micropattern includes various microfeatures;
• (b) characterizing the physical properties of the microfeatures;
• (c) characterizing a second material, wherein the second material is an uncured thermoset polymer or viscous thermoplastic polymer used for creating a part, and wherein the characterization of the second material includes:
• (i) measuring a degradation temperature of the polymer;
• and
• (ii) measuring a curing temperature of the polymer;
• (d) flowing the polymer into the microfeatures to form a polymer-metal combination;
• and
• (e) applying a gravitational or compressive force to the polymer-metal combination until an interface between the polymer and the metal has solidified and the materials have been joined.