Basic research on intrinsically produced FRP-/metal-composites - from embedded inserts to load-bearing hybrid structures

该项目的第二阶段“内在制造玻璃钢/金属复合材料的基础研究——从嵌入式嵌件到承重混合结构”涉及玻璃钢/钢结构部件的生产、表征和模拟。所有项目参与者首先将在项目第一阶段中获得的知识转移到负载引入元素，这些元素是准时的和线性的，用于差分设计。这是基于几个插入件和随后附加的金属帽轮廓的组合，以便获得具有金属支撑部件的混合部件。由此推导出一个整体混合结构。碳纤维增强塑料/钢结构部件应本质混合，即在直接生产过程中。这种杂交基于帽形钢叶片的使用，它将通过纤维插入，从而使结构负载以最佳方式引入CFRP层压板。因此，金属部件在部件中接受承载功能，其在承载能力方面提供了内在的制造优势。结合两种材料的优点，可以增加比能量吸收能力和轻建筑潜力。例如，可能的应用是汽车车身部件，如侧面碰撞载体、b柱或横向或纵向载体。wbk -生产工程研究所处理微分和整体设计的生产。整体结构的内在生产涉及对相关工艺参数的系统研究，以实现可重复性和高样品质量，从而建立对复杂部件的全面工艺理解。此外，还研究了不同的引入概念和安装位置以及玻璃钢与金属的最佳比例。应用材料研究所（IAM-WK）关注的是靠近结构部分的应力作用下的整体和差分承载结构的研究，包括根据各自的损伤演变进行调查，以获得对过程-结构-性能关系的全面理解。汽车系统技术研究所（FAST）在考虑生产效果的情况下，对混合动力部件在准静态弯曲应力作用下的充型、残余应力和失效行为进行了预测。材料的行为是通过使用在热载荷和机械载荷下的位移和膨胀场的全场光学测量来表征的。并将结构仿真与工艺仿真相结合，对混合结构和制造工艺进行整体优化。

Phase II of the project "basic research of intrinsically made FRP-/metal composites - from the embedded insert to load-bearing hybrid structure" deals with the production, the characterisation and the simulation of a CFRP/steel structural component. All project participants first transfer the knowledge gained in phase I of the project on load introducing elements, which are punctual and linear, to a differential design. This is based on the combination of several inserts and a subsequently attached metallic hat profile so as to obtain a hybrid component with a metallic, supporting component. An integral hybrid structure is to be derived from this. The CFRP/steel structural components should be intrinsically hybridised, i.e. in a direct production process. This hybridization is based on the use of a steel blade in the form of a hat profile, which is to be inserted by fiber in such a way that a structural load is optimally introduced into the CFRP laminate. Thus, the metallic component accepts a load-bearing function in the component, which provides by the intrinsic manufacturing advantages in terms of load capacity. By combining the advantages of both materials, the specific energy absorption capacity and the light construction potential can be increased. Possible applications are, for example, automobile body components, such as side impact carriers, B-pillars or transverse or longitudinal carriers. The wbk - Institute for Production Engineering deals with the production of differential and integral designs. The intrinsic production of the integral structure involves a systematic study of the associated process parameters in order to achieve a reproducible and high sample quality and thus to build up a comprehensive process understanding for complex components. Moreover, different introduction concepts and installation positions and an optimum ratio of FRP and metal are to be investigated. The institute for applied materials (IAM-WK) is concerned with the study of the integral and differential bearing structures under stresses close to the structural part, including the investigation according to the respective damage evolution, in order to obtain a comprehensive understanding of the process-structure-property relations. The institute of vehicle system technology (FAST) deals with the prediction of mold filling, residual stresses and failure behavior of the hybrid component under quasi-static bending stress, taking into consideration the production effects. Material behavior is characterized by using full-field optical measurement of the displacement and expansion field of samples exposed to thermal and mechanical loads. Furthermore, the structure simulation is coupled with the process simulation in order to be able to optimize the hybrid structure and the manufacturing process in a holistic way.