Project Details
Projekt
Intrinsic hybrid composites for crash-relevant structural parts processed by forming
Applicants
Professor Dr.-Ing. Welf-Guntram Drossel; Professor Dr.-Ing. Jörn Ihlemann; Professor Dr.-Ing. Thomas Lampke; Professor Dr.-Ing. Martin Franz-Xaver Wagner
Subject Area
Primary Shaping and Reshaping Technology, Additive Manufacturing
Term
from 2014 to 2021
Project identifier
Deutsche Forschungsgemeinschaft (DFG) - Project number 255883585
Despite an enormous potential for applications, hybrid parts for crash-relevant structures are not well established in the automotive industry. The complex and expensive manufacturing process as well as the difficult material testing, simulation and dimensioning of such composites prevent their utilization in commercial production. However, the results of the collaborative research of the first funding period demonstrate that crash-relevant structural parts made of intrinsic hybrid composites can be realized. To this end, a hybrid composite made up of a continuous fiber reinforced plastic (FRP), in which a metallic insert is integrated, was developed. The connection between the FRP and the metallic insert was generated by a combination of a geometrical form fit and adhesive bonding. On the one hand, adhesive bonds were based on a specially devised sol-gel process. On the other hand, local form fit elements were pressed into the FRP within the global forming process. Consequently, the hybridization, the forming of the part geometry and the generation of the form fit elements were performed in a single production step. In this context, precise simulations and newly developed methods for the experimental characterization of the components formed the basis for the dimensioning of the intrinsic hybrid composite. The main research goal for the second funding period is the systematic enhancement of the crash structure as well as the increase of the internal complexity of the composite. Therewith, the key objective is the transfer of the developed hybrid composite to series application and series production. This requires robust production processes while taking the increased complexity of the composite structure into account. Furthermore, the impacts both of production and later application on the properties of the resulting composite have to be identified and analyzed. To this end, these influences are considered in the simulation models. Finally, design proposals will be developed based on in-depth simulative and experimental characterizations. Thereby, the interface between the FRP and the metallic insert has to be considered in detail. Only a specific adjustment of this component, which significantly influences the strength of the composite, leads to maturity for series production and application. The collaboration between the different research centers makes it possible to comprehensively handle the topic intrinsic hybrid composites for crash-relevant structural parts, and to further establish processing technology of hybrid parts.
DFG Programme
Priority Programmes
