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

与传统的成型工艺如粘接和铆接技术相比，很少研究金属元件和纤维增强聚合物（FRP）之间的机械互锁方法。材料和生产为导向的设计方法的内在杂交显示出非常高的潜力，是一个有前途的基础，为开发新的创新轻质接头。机械联锁允许将极端载荷施加到杆形和管状FRP结构中，例如拉伸杆、压力罐、轴结构、轴驱动装置。异型接头特别适合承受轴向力和弯矩。该项目的目标是开发具有负载优化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一个综合的尺寸系统，考虑到现实的组件负载。本征混合结构的制造过程基于具有等温工具温度控制的整体吹塑工艺。本征过程方法的目的是在将复合材料连接到金属结构的同时固结带预制件，研究的重点是在高冷却速率下固结过程中的制造过程建模策略的发展，以及联锁混合结构的损伤起始和扩展行为的分析。先进的设计指南轮廓接头拉伸和压缩载荷的开发通过实验研究，考虑到中间和组合的热，以及静态和循环的机械载荷。

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.