Intrinsic Hybrid Composites for Lightweight Structures: New Process Chain Approaches

Koch, Simon Frederik; Barfuss, Daniel; Bobbert, Mathias; Groß, Lukas; Grützner, Raik; Riemer, Matthias; Stefaniak, Daniel; Zheng, Wenzhong

doi:10.4028/www.scientific.net/amr.1140.239

Cited by 20 publications

(14 citation statements)

References 13 publications

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“…A turbulent motion of the grits achieves a mild abrasion and removal of the substrate. With the help of an automated facility, the material's feed rate and the grit flow can be controlled to guarantee consistent process conditions [3]. The process proved to be reliable and provides comparably high shear strength values when comparing to chemical and conventional grit-blasting pre-treatments [15].…”

Section: Methodsmentioning

confidence: 99%

“…Fiber metal laminates (FML) are hybrid composite materials consisting of metal sheets co-cure bonded to fiber reinforced plastic layers (FRP). No additional joining process is needed as adhesion is realized by the resin during its cure [1][2][3]. The resulting properties of the hybrid material need to be predictable when used in structural applications.…”

Section: Introductionmentioning

confidence: 99%

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Evaluation of residual stress development in FRP-metal hybrids using fiber Bragg grating sensors

Prussak

Stefaniak

Hühne

et al. 2018

Prod. Eng. Res. Devel.

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This paper presents experimental measurement methods for the determination and evaluation of process related thermal residual stresses in fiber metal laminates. A cure monitoring system with fiber Bragg grating (FBG) sensors is used to measure the in-plane strains during processing of carbon fiber reinforced plastic (CFRP)-steel laminates. The simultaneous measurement captures the thermal expansion during the heating stages, the cure shrinkage, and the cooling thermal shrinkage. The results enable the characterization of the co-cure bonding process and the stress transfer between the metal and FRP-layers during the creation process. The residual strains, which are used for calculation of the residual stresses, are recorded at room temperature after manufacturing. In addition, an advanced method using FBG-sensors and the deflection of asymmetric hybrid specimens was developed to validate the gained residual stress data. Asymmetrical specimens are created by removing selected layers after cure. Quantitative evaluation is achieved by determination of their curvature and measuring the strain changes with the embedded FBG-sensors. For validation, the methods were successfully demonstrated on two different curing cycles with different resulting residual stress levels. The simultaneous strain measurement enables the investigation of stress development and delivers more in-depth process knowledge for further optimization of the manufacturing process.

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Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Evaluation of residual stress development in FRP-metal hybrids using fiber Bragg grating sensors

Prussak

Stefaniak

Hühne

et al. 2018

Prod. Eng. Res. Devel.

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“…Recent research activities have shown, that the gluing step can be integrated into the impregnation stage of the resin transfer moulding (RTM) process [13][14][15]. There, the metal component is placed inside the mould at the same time as the textile preform.…”

Section: Introductionmentioning

confidence: 99%

Flow-speed-controlled quality optimisation for one-shot-hybrid RTM parts

Hergan

Fauster

Perkonigg

et al. 2020

Advanced Manufacturing: Polymer & Composites Science

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This work describes a model-based methodology to improve the bonding quality between the metal and composite constituents of one-shot-hybrid resin transfer moulding (OSH-RTM) parts. In order to reduce void induced defects in the interface an ideal flow front velocity needs to be achieved. This ideal flow front velocity is characterised by capillary rise experiments at the used carbon fibre textile. The flow front velocity during mould filling is controlled by the use of pressure sensors and Darcy's law. Therefore, viscosity characterisation of the resin system and permeability measurements of the preform were carried out. The interface of the produced OSH-RTM roof bar for a car is tested on a component test rig imitating the load of a side impact at a car. A t-test was carried out to prove that the flowspeed-controlled injection strategy is advantageous compared to a constant mass flow injection by means of a higher maximum load transferable by the interface of the hybrid part.

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“…Consequently, one of the main focuses in the automotive industry should be on the development of new and efficient manufacturing and joining methods, and their integration into existing industrial processes. 9 For the production of such metal-FRP hybrid structures, intrinsic manufacturing techniques that integrate the joining process into the forming process of the FRP or the sheet metal, and thus enable a flat force transmission, are a convincing process technology. Common intrinsic manufacturing processes for hybrid structures are autoclave technologies, pressing technologies and resin injection processes, in which thermosetting and thermoplastic resins are used.…”

Section: Introductionmentioning

confidence: 99%

On the strength of joints of metal-plastic composites of hot-formed steel with an AlSi coating and a thermosetting fiber reinforced compression material

Wehler

Moritz

Fischer

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part D:

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Novel manufacturing techniques and application of new hybrid materials in the automotive industry increase the challenges in adhesive bonding. One of these is the bonding of coated materials such as high-strength steel with an aluminum-silicon (AlSi) coating, which is mostly used in safety-relevant components such as the front or side bumpers. To further improve the mechanical properties, these steel structures can be locally reinforced with a fiber-reinforced compression molding compound (SMC). In this process, the SMC is pressed directly onto the structure, without any pre-treatment of the surface of the steel, whereby the thermosetting resin matrix forms an adhesive bond with the AlSi coating. The choice of a suitable base resin system is of decisive importance for the joint strength of such directly joined hybrid composites and thus also for the overall performance. Therefore three SMC formulations with different base resins were tested for direct adhesion to a metallic surface of a hot-formed steel with an AlSi coating. The aim of this investigation is to identify a correlation between energetic as well as optical surface characteristics and the mechanical strength of such direct hybrid joints. Furthermore, it shall be examined whether a modification of the base resin in the polymer has a significant influence on the bonding strength and the fracture pattern. For this, the project focuses on new methods for the mechanical testing of metal-plastic hybrid composites.

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Intrinsic Hybrid Composites for Lightweight Structures: New Process Chain Approaches

Cited by 20 publications

References 13 publications

Evaluation of residual stress development in FRP-metal hybrids using fiber Bragg grating sensors

Evaluation of residual stress development in FRP-metal hybrids using fiber Bragg grating sensors

Flow-speed-controlled quality optimisation for one-shot-hybrid RTM parts

On the strength of joints of metal-plastic composites of hot-formed steel with an AlSi coating and a thermosetting fiber reinforced compression material

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