Hybrid Fibre Reinforced Thermoplastic Hollow Structures with a Multi-Scale Structured Metal Load Introduction ElementWednesday (29.04.2020) 11:40 - 12:00 Room 1
Profile and contour joints of composite / metal hybrid structures offer promising potential for novel lightweight hybrid structures. Above all, joining systems with a form closure function enable the introduction of very high loads into rod- and tube-shaped fibre-reinforced structures and achieve high degrees of material utilization for the composite part. Intrinsic productions strategies, which join and consolidate in one and the same step, enable significant cycle time reduction by shortening of the process chain compared to established technologies for joining fibre reinforced materials with metallic structures. This paper presents a new process approach for the highly efficient, automated production of hollow profiles of fibre reinforced-thermoplastic composites with an integrated metallic load introduction element. The hybrid structures are produced in an integral blow moulding process in which a braided tape-preform is simultaneously consolidated and formed into the metallic load introduction element. These metallic load introduction elements with multiscale form closure are manufactured in a two-phase high-pressure forming process. Numerical investigations on the macro- and generic microscale demonstrate the potential to trigger cohesive or adhesive failure by appropriate designed form closure elements. The extensive experimental investigations of the joint strength of meso-, macro- or combined-structured tubular specimen show the beneficial effect of multi-scale structuring to increase the joining strength. Concluding advises for the contour joints design are given.