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WEB Intrinsic Hybrid Composites for Lightweight Structures – Fundamentals of Manufacturing, Characterisation and Design – Priority Program 1712

Wednesday (29.04.2020)
09:45 - 10:05 Room 2

In times of awareness of finite energy resources, increasing mobility and stricter environmental laws, lightweight components make a contribution to sustainable development in terms of resource consumption. The use of lightweight solutions reduces the energy consumption of moving systems and increases the payload of a wide variety of applications. Fibre-reinforced plastics in particular, offer excellent mass-related stiffness and strength and therefore contribute to a significant weight reduction. However, if a high elongation or thermal stability are required, the use of metallic materials is preferred. This shows that a complete substitution of a material for the consistent use of lightweight potential is not always the best solution. The optimum overall structure consists of a hybrid material combination of a metallic and an endless fibre-reinforced component, the so-called multi-material design. The approach of hybridizing structural components is thus becoming more and more important and can basically be achieved according to two different methods. On the one hand, hybrid composites can be joined by downstream process steps, such as riveting or screwing. The disadvantage of this approach is the additional mass, which means that the lightweight potential cannot be fully exploited. An alternative possibility is production in a single-stage process, in which the various materials are joined by moulding or forming without a subsequent joining process. The resulting component of this single-stage process is called an intrinsic hybrid composite. The focus of this presentation is the Priority Program 1712 Intrinsic Hybrid Composites for Lightweight Structures - Fundamentals of Manufacturing, Characterization and Design, where various components such as hybrid hollow structures, crash profiles or insert components are investigated in eight different projects. Interdisciplinary cooperation between the various disciplines of mechanics, production engineering and materials science enables the challenges of intrinsic hybrid composites to be solved and transferred to complex components. Besides, two cross-project working groups deal with design guidelines and production technologies for intrinsic hybrid composites. The overall results of this cross-project working groups will be part of this presentation as well as a detailed comparison between intrinsic and extrinsic technologies and an outlook on future challenges in the field of fibre reinforced plastics.

Prof. Dr. Jürgen Fleischer
Karlsruhe Institute of Technology (KIT)


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