Process chain for forming and consolidating fiber-reinforced thermoplastics and metallic sheets in a two-stage isothermal tool

Abstract

Due to their good mechanical properties and low structural weight, multi-material structures are a promising approach in the automotive industry to lightweight design, body construction and functionalization. Especially metal and plastic are mainly combined to achieve improved properties of the final component compared to mono-material structures. This paper describes the development of a manufacturing cell for the joint forming and heat-assisted press joining of steels and continuous fiber-reinforced thermoplastics in the form of unidirectional carbon-fiber tapes. In order to achieve shorter cycle times and to ensure economical production, a manufacturing cell, supplemented with automated handling by means of two robots and an isothermal, two forming stages tool concept was developed and tested. The composite components produced were tested with regard to their mechanical performance. The feasibility of the production was demonstrated. All composite components had a higher specific load capacity than a pure steel component. Cycle times of well under 60 seconds were achieved. An enormous reduction in process time compared to variothermal tool concepts could be achieved with the new manufacturing cell.