Energy-efficient manufacturing and mechanism-based characterization of the corrosion fatigue behavior of laser-structured hybrid composites

• Applicants: Dr. Jan Haubrich; Professor Dr. Thomas Tröster; Professor Dr.-Ing. Frank Walther
• Subject Area: Polymeric and Biogenic Materials and Derived Composites ; Materials in Sintering Processes and Generative Manufacturing Processes ; Mechanical Properties of Metallic Materials and their Microstructural Origins
• Term: from 2019 to 2024
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 426499947

The aim of the research project by addressing the mobility sector is the development and characterization of intrinsic bonded and corrosion-resistant CFRP/Al 6082-hybrid composites for the application in higher loaded car body parts. Modern cars are multimaterial designs nowadays, although the manufacturing of hybrid composites requires a lot of mostly manual work steps and high standards concerning methodology, autoclave processing and prevention of contamination during processing, resulting in high costs. Furthermore, internal stresses in the structural element and the electrochemical isolation of the individual components to avoid contact corrosion between carbon fibers and metal (e.g. CARALL) must be considered. In the research project, besides this applicationoriented efficiency enhancement through lightweight construction, the manufacturing process of the hybrid components as well as thecharacterization will be designed energy-efficiently. Therefore, the intrinsic material bond between fiber-reinforced plastic and metallic components as well as forming of the final structural element will be realized in one work step, to reduce needed process steps and time. Concerning fatigue and corrosion behavior, the effectiveness of laser structuring of the metallic joining surfaces will be investigated over instrumented corrosion fatigue tests. With the help of mechanismbased characterization of the deformation behavior, basic knowledge about aging and damage processes will be build up. On the basis of cooperative pre-work the combination of the alloy Al 6082-T6 with carbon fibers (fiber type: SGL C30 T050 342 EPY) and epoxy resin E201 (SGL Group) was chosen as model system. The project structure implicates the expertise and research of the three Project partners concerning manufacturing of hybrid composites (LiA), joining processes and interface analysis (DLR) as well as measurement and test methodology with regard to the corrosion fatigue behavior (WPT). The aim of the project can only be realized by the interdisciplinary exchange of results and data.

• DFG Programme: Research Grants