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

该项目的第一阶段旨在开发一种制造纤维金属层板(FML)的一步法工艺，该工艺可以在基础实验和纤维金属层板零件的制造中实现。该工艺有助于减少制造纤维金属层压板的时间和成本。为了实现这一新的制造方法，开发并使用了湿压和树脂传递模塑两种工艺路线。在金属坯料之间的纤维中注入反应性热塑性基质。聚合反应在成型过程中开始，导致纤维与金属坯料之间的界面粘结。因此，半成品材料的几何形状的选择是灵活的，可以组合不同的几何形状，而不依赖于供应商的材料组合。然而，零件的结构并没有在载荷起始方面进行优化。轻量化设计的潜力还没有实现。第二阶段，瞄准轻量化潜力和高度柔性组合的潜力，开发和制造具有定制性能的纤维金属层合板。在这种策略下，可以生产出在所需位置和所需方向上使用材料的载荷优化和功能分级零件。在金属毛坯成形领域，这种方法被称为“剪裁毛坯”。由于混合式结构，零件不能均匀渗透，因此，有必要在成形过程中了解基质系统的流动情况，以确保纤维的正确渗透。在第一个资助期内，可以在成形实验中间接研究流动情况。除了制造定制纤维金属层板的目标外，第二个资助期将专注于非均匀纤维层在定制纤维金属层板中的渗透的实验和数值研究。由于织物层数的变化会导致填充的变化，因此，在成形过程的模拟中将填充模拟集成在一起。需要关于纺织品渗透性的详细信息依赖于纤维体积含量，而纤维体积含量本身依赖于纤维紧实度和剪切角。因此，填充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取向不均匀的情况，可以预测基质的填充情况，这是原位杂交过程中的一个额外价值。

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.