Fig. 1 Polymer-aluminum hybrid structure (geom-etry of the double-lap joint prior to testing)

Fig. 2 Filling simulation of the polymer-aluminum double-lap joint (shear test specimen)

Fig. 3 Setup for annealing the double-lap joint

Fig. 4 Fitting possibilities between polymer and aluminum; left: force-fit right: adhesive bond manufactured by injection molding

Fig. 5 Initial surface roughness of a polymer film and aluminum sheet before joining by a force fit measured by WLI

Fig. 6 Leak tightness of injection molded double-lap joints (polymer-aluminum hybrids) compared to a force fitted joint and a mas-sive aluminum sheet

Fig. 7 Shear strength of polymer-aluminum dou-ble-lap joints non-annealed and differently annealed

Fig. 8 DSC traces of TPE-S pellet and injection molded samples (IM)

Fig. 9 LM micrograph of the interface between polymer and aluminum

Fig. 10 SEM micrographs of the interface between polymer and aluminum after different an-nealing conditions

Fig. 11 Shear test fracture pattern of differently annealed double-lap joints

Fig. 12 SEM fracture pattern micrograph of a dou-ble-lap joint annealed at 120°C for 2 h