Development of the theoretical and technological fundamentals for intrinsic thermoplastic composite/metal hollow profiles with load-adapted cross-scale form fit

与粘接和铆接技术等传统成型工艺相比，很少有人研究在金属元素和纤维增强聚合物(FRP)之间采用机械联锁的方法。面向材料和生产的本征混杂材料的设计方法显示出很大的潜力，是开发新型创新轻质接头的良好基础。机械联锁允许将极端载荷施加到杆状和管状玻璃钢结构中，例如拉杆、压力罐、轴结构、轴驱动。轮廓接头特别适合承载轴向力和弯矩。该项目的目标是开发具有负载优化的多尺度机械联锁的固有热塑性金属中空结构的理论和技术原理(见图)。该项目的主要重点是开发考虑实际构件载荷的综合尺寸标注系统。本征混杂结构的制造工艺是基于整体吹塑工艺和等温工具温度控制。本征工艺方法的目标是在将复合材料连接到金属结构的同时进行带-预制件的固结，重点研究在高冷却速率固结过程中的制造过程的建模策略，以及联锁混合结构的损伤萌生和扩展行为的分析。通过实验研究，制定了拉伸和压缩载荷的轮廓连接的高级设计指南，其中考虑了中间和组合热载荷，以及静态和循环机械载荷。

In contrast to conventional forming processes as adhesive and riveting technologies, approaches with a mechanical interlock between the metal element and fibre-reinforced polymers (FRP) are rarely investigated. The material- and production-oriented design approach of intrinsic hybrids show very high potential and are a promising basis for the development of novel innovative lightweight joints. A mechanical interlock allows the application of extreme loads into rod-shaped and tubular FRP structures, for instance tensile bars, pressure tanks, axis structures, shaft drives. Contour joints are particularly suitable for carrying axial oriented forces and bending moments.The objective of the project is the development of the theoretical and technological principles for intrinsic thermoplastic-metal hollow structures with load-optimised multiscale mechanical interlock (see Figure). The main focus of the project is on the development of a comprehensive dimensioning systematic considering realistic component loads. The manufacturing process of the intrinsic hybrid structure is based on an integral blow moulding prosess with isothermal tool temperature control. The intrinsic process approach aims at consolidating the tape-preform simultaneously to joining the composite to the metal structure.Focus of the investigations is the development of modelling strategies for the manufacturing processes during the consolidation with high cooling rates, as well as the analysis of the damage initiation and propagation behaviour of interlocking hybrid structures. Advanced design guidelines for contour joints for tensile and compressive loads are developed by means of experimental investigations, taking into account medial and combined thermal, as well as static and cyclic mechanical loads.