Intrinsic hybrid composites for crash-relevant structural parts processed byforming

尽管有巨大的应用潜力，但用于碰撞相关结构的混合动力部件在汽车工业中还没有很好地建立起来。复杂和昂贵的制造工艺以及这种复合材料的困难的材料测试、模拟和尺寸确定阻碍了它们在商业生产中的应用。然而，第一个资助期的合作研究结果表明，可以实现由本征混合复合材料制成的碰撞相关结构部件。为此，开发了一种由连续纤维增强塑料（FRP）制成的混合复合材料，其中集成了金属插入件。FRP和金属嵌件之间的连接是通过几何形状配合和粘合剂结合来产生的。一方面，粘合剂的结合是基于一个专门设计的溶胶-凝胶过程。另一方面，在整体成形过程中，将局部形状配合单元压入FRP中。因此，混合、零件几何形状的形成和形状配合元件的生成在单个生产步骤中进行。在这种情况下，精确的模拟和新开发的方法的实验表征的组件形成的基础上的内在的混合复合材料的尺寸。第二个资助期的主要研究目标是系统地增强碰撞结构以及增加复合材料的内部复杂性。因此，关键目标是将所开发的混杂复合材料转移到系列应用和系列生产。这需要稳健的生产工艺，同时考虑到复合结构的复杂性增加。此外，必须确定和分析生产和后续应用对所得复合材料性能的影响。为此，在仿真模型中考虑了这些影响。最后，设计方案将根据深入的模拟和实验表征。因此，必须详细考虑FRP和金属嵌件之间的界面。只有对该组分进行特定的调整，才能显著影响复合材料的强度，从而使系列生产和应用变得成熟。不同研究中心之间的合作使全面处理用于碰撞相关结构部件的本征混杂复合材料主题成为可能，并进一步建立混杂部件的加工技术。

Despite an enormous potential for applications, hybrid parts for crash-relevant structures are not well established in the automotive industry. The complex and expensive manufacturing process as well as the difficult material testing, simulation and dimensioning of such composites prevent their utilization in commercial production. However, the results of the collaborative research of the first funding period demonstrate that crash-relevant structural parts made of intrinsic hybrid composites can be realized. To this end, a hybrid composite made up of a continuous fiber reinforced plastic (FRP), in which a metallic insert is integrated, was developed. The connection between the FRP and the metallic insert was generated by a combination of a geometrical form fit and adhesive bonding. On the one hand, adhesive bonds were based on a specially devised sol-gel process. On the other hand, local form fit elements were pressed into the FRP within the global forming process. Consequently, the hybridization, the forming of the part geometry and the generation of the form fit elements were performed in a single production step. In this context, precise simulations and newly developed methods for the experimental characterization of the components formed the basis for the dimensioning of the intrinsic hybrid composite. The main research goal for the second funding period is the systematic enhancement of the crash structure as well as the increase of the internal complexity of the composite. Therewith, the key objective is the transfer of the developed hybrid composite to series application and series production. This requires robust production processes while taking the increased complexity of the composite structure into account. Furthermore, the impacts both of production and later application on the properties of the resulting composite have to be identified and analyzed. To this end, these influences are considered in the simulation models. Finally, design proposals will be developed based on in-depth simulative and experimental characterizations. Thereby, the interface between the FRP and the metallic insert has to be considered in detail. Only a specific adjustment of this component, which significantly influences the strength of the composite, leads to maturity for series production and application. The collaboration between the different research centers makes it possible to comprehensively handle the topic intrinsic hybrid composites for crash-relevant structural parts, and to further establish processing technology of hybrid parts.