Intrinsic production of hybrid components utilizing a modified RTM-process

该研究项目的主要目标是将第一个供资期（FP 1）开发的内在制造工艺概念转移到复杂结构、真实的载荷条件和大规模生产中。内部加强的B柱以及外部加强的传输通道被视为示范。为了确保在高温下完全浸渍预成型件并缩短循环时间，必须提高注射压力。非常重要的是实现均匀的界面层。该层充当载荷传递元件，因此主要影响混合结构的整体功能。此外，在第一次FP过程中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。此外，还将研究一种自密封工具概念，它可以补偿部件公差，并允许更换易磨损的硅密封。最后，在FP 1中所追求的八字螺柱概念将扩展到3D结构。为此，必须开发灵活的锚固机制，确保减少干涉轮廓，选择合适的表面预处理，并测试额外的工具运动学。在材料科学领域，FP 1中用于提高附着力的激光成型技术不适用于3D几何形状。为了形成预先结构化的金属板，必须开发抗变形结构。此外，激光束的非正交照射导致不均匀的结构化，这必须避免。此外，在FP 1中，发现了激光和加载方向之间的依赖性，因此应研究负载调整的结构化。三维混合结构的循环载荷、碰撞载荷和老化会导致复杂的失效机制，这一点应在FP 2中进行研究。因此，必须开发合适的测试方法。这些数据用于表征材料并确定模拟的特征值。工艺开发基于对工艺步骤的描述，这些描述是通过实验建立的建模和模拟。为了宏观确定复杂混合部件成型填充过程中的流动前沿，目标是固化和流动行为的耦合。真实的加载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而不是混合部件的老化来描述。为了模拟混合结构在老化影响下的碰撞行为，发展了均匀化方法。此外，老化与失效机制相结合。

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.