Intrinsic hybrid composites for crash-relevant structural parts processed byforming

尽管有巨大的应用潜力，但在汽车行业，与碰撞相关的结构的混合部件并不是很成熟。这种复合材料复杂而昂贵的制造工艺以及难以进行的材料测试、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，用本征混杂复合材料制造与碰撞相关的结构部件是可以实现的。为此，开发了一种由连续纤维增强塑料(FRP)组成的混杂复合材料，其中集成了一个金属插件。玻璃钢和金属嵌件之间的连接是通过几何形状配合和粘接结合产生的。一方面，粘结剂是基于一种特殊设计的溶胶-凝胶工艺。另一方面，在整体成形过程中，局部形式的配合单元被压入玻璃钢。因此，在单个生产步骤中完成了杂交、零件几何形状的形成和形状配合元素的生成。在这种背景下，精确的模拟和新开发的组元实验表征方法形成了本征混杂复合材料的尺寸基础。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，关键的目标是将所开发的混杂复合材料转化为系列化应用和系列化生产。这需要强大的生产过程，同时考虑到复合材料结构的日益复杂。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，将在深入的模拟和实验表征的基础上提出设计建议。因此，必须详细考虑玻璃钢和金属嵌件之间的界面。只有对这种显著影响复合材料强度的成分进行特定的调整，才能达到批量生产和应用的成熟度。不同研究中心之间的协作使全面处理碰撞相关结构部件的固有混杂复合材料这一课题成为可能，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.