Determined adjustment of tailored properties by using the In situ Hybridization of the manufacturing of thermoplast-based tailored fiber metal laminates

项目第一期的目标是开发一种用于纤维金属层压板（FML）制造的一步工艺，该工艺可以在基础实验和纤维金属层压板零件的制造中实现。该工艺有助于减少制造金属纤维层压板的时间和成本。为了实现这种新的制造方法，开发并应用了湿压和树脂传递成型两种工艺路线。在金属毛坯之间的纤维中注入活性热塑性基质。聚合在成形过程中开始，在纤维和金属坯料的交界面形成键合。因此，半成品材料的几何形状的选择是灵活的，不同的几何形状可以组合，而不依赖于供应商的材料组合。然而，在载荷启动方面，零件的结构没有得到优化。轻量化设计的潜力尚未实现。第二阶段，针对轻量化潜力和高柔性组合潜力，开发和制造具有定制性能的金属纤维层压板。在这个策略中，在需要的位置和需要的方向上使用材料来生产负载优化和功能分级的部件。在金属坯料成形领域，这种方法被称为“定制坯料”。由于混合结构，零件不能均匀渗透。因此，在成形过程中，有必要了解基体体系的流动情况，以确保纤维的正确浸润。在第一个资助期，流动可以在成形实验中进行间接研究。除了实现定制金属纤维层压板的制造目标外，第二阶段的资助将重点进行定制金属纤维层压板中非均匀纤维层渗透的实验和数值研究。为了实现这一目标，由于织物层数的变化会导致填充量的变化，因此将填充模拟集成到成型过程的模拟中。纺织品的透气性与纤维体积含量有关，而纤维体积含量又与纤维的压实度和剪切角有关。因此，充填模拟将与成形模拟相结合。不仅对于均匀的织物层，特别是对于纤维层的数量和方向不均匀的情况，可以预测基体的填充，这是原位杂交过程的附加价值。

The first period of the project targeted the development of a one-step process for the manufacturing of fiber metal laminates (FML), which could be realized in basic experiments and the manufacturing of fiber metal laminate parts. This process helps decreasing the time and cost for the manufacturing of fiber metal laminates. For the realization of this new manufacturing method, two process routes using the wet pressing and the resin transfer molding were developed and used. A reactive thermoplastic matrix is injected in the fibers between the metal blanks. The polymerization starts during the forming process, which causes the bonding in the boundary surface between the fibers and the metal blanks. Therefore, the selection of the geometry of the semi-finished material is flexible and different geometries can be combined without being dependent on material combination of suppliers. However, the structure of the parts is not optimized regarding the load initiation. The potential of lightweight design is not realized, yet.In the second period, the lightweight potential and the potential of highly flexible combinations are targeted, so that fiber metal laminates with tailored properties are developed and manufactured. Within this strategy, load optimized and functionally graded parts using material in needed positions and in needed orientations are produced. In the field of metal blank forming, this method is known as “tailored blanks”. Due to the hybrid architecture, the part can not be infiltrated homogenously.Therefore, it is necessary to know the flow of the matrix system during the forming operation to ensure the correct infiltration of the fibers. In the first funding period the flow could be investigated indirect in forming experiments. Beside the aim of the manufacturing of tailored fiber metal laminates, the second funding period will focus on the experimental and the numerical investigation of the infiltration of inhomogeneous fiber layers in tailored fiber metal laminates. For the realization, the filling simulation will be integrated in the simulation of the forming process because the variation of layers of fabrics causes variations in filling. Detailed information concerning the permeability of the textiles in dependency of the fiber volume content which itself is dependent of the fiber compaction and the shear angle are needed. As a result, the filling simulation will be combined with the forming simulation. Not only for homogeneous layers of fabrics but especially for inhomogeneous amount and orientations of fiber layers, the filling of the matrix can be predicted, which is an additional value for the process of the in-situ hybridization.