Intrinsic production of hybrid components utilizing a modified RTM-process

该研究项目的主要目标是将内在制造过程的开发概念从第一个资助期（FP 1）转移到复杂结构，实际负载条件和大规模生产中。内部加固的b柱和外部加固的传输隧道被认为是示范。为了确保预成型在高温下完全浸渍并减少循环时间，必须增加注射压力。同质接口层的实现是非常重要的。该层作为荷载传递单元，主要影响混合动力结构的整体性能。此外，在第一次FP期间为减少残余应力而开发的金属和FRP侧的不同加热将转移到复杂的几何形状上。此外，将研究一种自密封工具概念，该工具可以补偿组件公差并允许替换易磨损的硅密封。最后，在FP 1中所追求的扩展螺柱概念将扩展到3D结构。为此，必须开发一种灵活的锚定机构，必须确保减少干涉轮廓，必须选择合适的表面预处理，并且必须测试额外的工具运动学。在材料科学领域，激光结构用于FP - 1以实现改善附着力是不可行的3D几何形状。对于先前结构的金属板的成形，必须开发一种抗变形结构。此外，激光束的非正交照射会导致结构不均匀，这是必须避免的。此外，在fp1中发现了激光与加载方向之间的依赖关系，因此需要研究负载调节结构。三维混合结构的循环载荷和碰撞载荷以及老化会导致复杂的破坏机制，这将在FP 2中进行研究。因此，必须开发合适的测试方法。这些用于表征材料并确定模拟的特征值。该工艺的开发是基于对工艺步骤的描述，通过实验建立良好的建模和仿真。对于复杂杂化构件充型过程中流动前沿的宏观确定，着眼于固化与流动特性的耦合。实际载荷条件对构件设计的影响是非常重要的。这种影响将通过模拟基体的老化来描述，而不是模拟混合构件的老化。为了模拟混杂结构在时效作用下的碰撞行为，提出了均匀化方法。此外，老化与失效机制是耦合的。

The main objective of the research project is to transfer the developed concept of an intrinsic manufacturing process from the first funding period (FP 1) to complex structures, real loading conditions and large-scale production. An internally reinforced B-pillar as well as an externally reinforced transmission tunnel are considered as demonstrators.In order to ensure a complete impregnation of the preform at elevated temperatures and to reduce the cycle times, the injection pressure has to be increased. Of great importance is the realization of a homogeneous interface layer. This layer acts as the load transmission element and thus mainly influences the overall function of the hybrid structures. Furthermore, the different heating of the metal and FRP side, developed during the first FP to reduce residual stresses, will be transferred to complex geometries. In addition, a self-sealing tool concept, which compensates for component tolerances and allows to replace the liable to wear silicon sealing will be studied. Finally, the splay stud concept, which is pursued in FP 1, is to be extended to 3D structures. For this purpose, a flexible anchoring mechanism has to be developed, a reduction of the interference contour has to be ensured, a suitable surface pretreatment has to be selected and additional tool kinematics have to be tested.In the field of materials science the laser structuring used in the FP 1 to achieve improved adhesion is not feasible for 3D geometries. For the forming of previously structured metal sheets a deformation-resistant structuring has to be developed. Moreover, non-orthogonal irradiation of the laser beam results in uneven structuring, which has to be avoided. Furthermore, in FP 1 a dependency between the laser and the loading direction was found, so that a load-adjusted structuring should be investigated. The cyclic and crash loadings and aging of the 3D hybrid structures, that should be examined in FP 2, cause complex failure mechanisms. Therefore suitable test methods have to be developed. Those are used to characterize the materials and to identify characteristic values for the simulation.The process development is based on the description of the process steps by experimentally well-founded modeling and simulation. For the macroscopic determination of the flow front during the form filling of complex hybrid components a coupling of curing and flow behavior is aimed. The influence of real loading conditions is very important for the component design. This influence will be described by the simulation of the aging of the matrix instead of the aging of the hybrid component. In order to simulate the crash behavior of the hybrid structure under the influence of aging, homogenization methods are developed. In addition the aging is coupled with the failure mechanisms.