The current trend shows an increasing demand for novel technologies, that facilitate a functional integration of fiber reinforced polymers (FRP) in metal based structures, especially in automotive industry. To comply with the requirements of large-scale production the use of fiber reinforced thermoplastics in form of hybrid metal/composite-laminates seems advantageous. By targeted exploitation of their high lightweight potential, combined with suitable capabilities for mass production and good damping properties, cost-effective and weight-optimized parts with high stiffness and load capacity can be provided for future applications. As there is little known about the processing and the mechanical properties of thermo-plastic based FRP/metal-laminates, the study focuses on the development of novel hybrid laminates with low residual stresses, made of metallic steel sheets and continuous glass or carbon fiber reinforced polyamide 6. In this context, the influence of several pre-operations like sand blasting, cleaning or primer application on the interlaminar shear strength (ILSS) was examined in addition to their resistance to cathodic dip paint treatment
Because of their high specific stiffness and strength, fiber reinforced plastics (FRP) are preferred lightweight materials. Recent developments show a growing industrial interest in the integration of thermoplastic FRP in complex structures for high volumes. However, there are still shortcomings for these materials concerning the insufficient energy absorption in case of failure and the limited opportunities available for the assembly with other components. Improvements in the crash performance can be achieved for instance with the selective reinforcement of the FRP structure with ductile metallic inserts. The present study shows the interlaminar shear strength and scanning electron microscope (SEM) samples of a novel load optimized hybrid composite consisting of a continuous fiber-reinforced thermoplastic matrix, in which a metal core is integrated.
Growing mechanical, economic and environmental specification lead to multi-material designs. Based on an extensive basic research, more achievements and experiences regarding the manufacturing technologies and mechanical properties of hybrid laminates were achieved in the Institute of Lightweight Structures and Polymer Technology. The present study shows the development, characterization and forming of novel hybrid laminates, made of steel sheets (HC220Y+ZE, t = 0.25 mm) and carbon fiber reinforced polymers (Polyamide 6). The interface-optimization of the hybrid laminates was carried out with two different bonding agents. The results of a three point bending test underline the potential of the innovative material. A hybrid roof crossmember was formed on a hydraulic Tryout-Press successfully.
A heavy-duty multi-material-design (MMD) can be realized through the combined use of structured sheet metal and reinforced plastics (FRP). To exploit the high lightweight potential of the various material groups within a multi-material system as efficient as possible, a material-adapted and particularly fiber adjusted joining method must be applied. The present paper primarily focuses on the manufacturing and mechanical testing of novel multi-material joints with structured sheet metals and carbon fiber reinforced thermoplastics (CFRP). For this purpose the applicability of the new Flow Drill Joining (FDJ) method, which was developed for joining of heavy-duty metal/composite hybrids, was investigated.
Reliable line production processes and simulation tools play a central role for the structural integration of thermoplastic composites in advanced lightweight constructions. Provided that material-adapted joining technologies are available, they can be applied in heavy-duty multi-material designs (MMD). A load-adapted approach was implemented into the new fully automatic and faulttolerant thermo mechanical flow drill joining (FDJ) concept. With this method it is possible to manufacture reproducible high strength FRP/metal-joints within short cycle times and without use of extra joining elements for the first time. The analysis of FDJ joints requires a simplified model of the joint to enable efficient numerical simulations. The present work introduces a strategy in modeling a finite-element based analogous-approach for FDJ-joints with glass fiber reinforced polypropylene and high-strength steel. Combined with a newly developed section-force related failure criterion, it is possible to predict the fundamental failure behavior in multi-axial stress states. The functionality of the holistic approach is illustrated by a demonstrator that represents a part of a car body-in-white structure. The comparison of simulated and experimentally determined failure loads proves the applicability for several combined load cases.
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