Project Details
Projekt
Multilayer-Inserts - Intrinsic hybrid materials for force transmission into thin-walled high performance CFRP-structures
Applicants
Professor Dr.-Ing. Berend Denkena; Professor Dr.-Ing. Peter Horst; Professor Dr.-Ing. Dieter Meiners
Subject Area
Primary Shaping and Reshaping Technology, Additive Manufacturing
Plastics Engineering
Lightweight Construction, Textile Technology
Plastics Engineering
Lightweight Construction, Textile Technology
Term
from 2014 to 2020
Project identifier
Deutsche Forschungsgemeinschaft (DFG) - Project number 256060127
Increasing demands on lightweight structures present major challenges for their design, materials and production technology. Production and assembly costs are as much of a driver in research and development as the weight reduction itself. This applies for force introduction elements as well.In lightweight structures out of fiber-reinforced plastics (FRP), the usage of metallic inserts as force introduction elements can enable improved designs, but available elements for pin load introduction into laminates usually are of simple geometry and are not optimized for the laminar structure of FRP. Furthermore, their integration process is mainly manual, increasing the production costs. Insufficient design methods and missing models for an adequate analysis complicate the development of apt solutions. During the selection of suitable materials several challenges have to be considered: electrochemical corrosion and the mechanical characteristics of the boundary layer between the combined materials are to be taken into account. Production technology faces the challenge of integrating these materials in existing FRP-processes efficiently and reliably.The objective of this project is to research the multilayer-insert (MLI) as a load introduction element for complex thin-walled structures under the aspects of the production process, the dimensioning and the boundary layer between metal and FRP-materials. Simulations and investigations on placing metal-layers with a module integrated in an AFP process will be conducted to determine process-driven requirements for production of curved structures. A simulation based approach for controlling and monitoring is used to increase the robustness of the process. Detailed simulations and experimental investigations determine the impact of effects induced by curvature, interaction of adjacent MLI and multiple connected MLI. Thin interface layers of thermoplastics and adhesive systems are investigated regarding their capability to reduce thermal induced tension. The transition zone between the interface layer and the epoxy resin, the application on the metallic insert and the tension reducing mechanism are analyzed. The technological potential for new areas of application are pointed out by combining and evaluating the methods, experimental test benches and prototype systems developed in each discipline.
DFG Programme
Priority Programmes
