Development of the theoretical and technological fundamentals for intrinsic thermoplastic composite/metal hollow profiles with load-adapted cross-scale form fit

• Applicants: Professor Dr.-Ing. Maik Gude; Professor Dr.-Ing. Markus Kästner; Dr.-Ing. Roland Müller
• Subject Area: Synthesis and Properties of Functional Materials ; Lightweight Construction, Textile Technology ; Mechanics ; Production Automation and Assembly Technology
• Term: from 2014 to 2018
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 256127863

In contrast to conventional forming processes as adhesive and riveting technologies, approaches with a mechanical interlock between the metal element and fibre-reinforced polymers (FRP) are rarely investigated. The material- and production-oriented design approach of intrinsic hybrids show very high potential and are a promising basis for the development of novel innovative lightweight joints. A mechanical interlock allows the application of extreme loads into rod-shaped and tubular FRP structures, for instance tensile bars, pressure tanks, axis structures, shaft drives. Contour joints are particularly suitable for carrying axial oriented forces and bending moments.The objective of the project is the development of the theoretical and technological principles for intrinsic thermoplastic-metal hollow structures with load-optimised multiscale mechanical interlock (see Figure). The main focus of the project is on the development of a comprehensive dimensioning systematic considering realistic component loads. The manufacturing process of the intrinsic hybrid structure is based on an integral blow moulding prosess with isothermal tool temperature control. The intrinsic process approach aims at consolidating the tape-preform simultaneously to joining the composite to the metal structure.Focus of the investigations is the development of modelling strategies for the manufacturing processes during the consolidation with high cooling rates, as well as the analysis of the damage initiation and propagation behaviour of interlocking hybrid structures. Advanced design guidelines for contour joints for tensile and compressive loads are developed by means of experimental investigations, taking into account medial and combined thermal, as well as static and cyclic mechanical loads.

• DFG Programme: Priority Programmes
• Subproject of: SPP 1712: Intrinsic Hybridcomposites for Lightweight Construction Structures - Basics of Manufacturing, Characterisation and Mechanical Design