Joining of metal and fibre components based on the semi-solid forming process

汽车工程中轻量化结构的趋势通过减少污染物排放和节约资源对环境保护做出了重大贡献。然而，这种发展在汽车制造中引起了额外的努力和更高的费用，因为新材料或新材料组合需要适应生产和加工方法。金属和纤维基结构（GRP-/ CFRP组件）的不同组合要求方便的连接方法。在这种情况下，本研究项目的目标是开发一种创新的连接方法，将金属板材与碳纤维增强塑料结构结合起来。拟议项目的目标是出于对这种方法的要求，以防止在连接过程中使用的纺织纤维结构的任何损坏。在半固态成形技术的基础上，开发了一种新的连接工艺，在纤维和金属构件之间建立一种材料集成键合。本研究方案中所描述的基础实验已经证明了这种新型连接技术的技术可行性。要进行的研究工作包括使用不同的板材合金：钢-铝、铝-铝和钢-钢的组合将与内部碳纺织品可靠地连接。随后，将通过光学和机械检查来分析所生产的混合结构的质量，此外，还必须研究金属板之间的反应，或者分别研究纤维和金属板之间的反应。利用ANSYS软件对新型复合材料进行了数值模拟。流体力学和结构力学过程由CFD和CSM程序计算。这样可以模拟粗纱的入渗情况。基于这些结果，应该可以进行复合材料强度的计算。通过这种方式，该项目将提供证据，证明制造连接的质量及其相关的所需工艺参数可以在连接过程之前计算出来。

The trend towards lightweight construction in automotive engineering contributes significantly to environment protection by reducing pollutant emissions and by conserving resources. However, this development causes additional effort and higher expense in vehicle manufacturing, because new materials or, respectively, new material combinations require adapted production and processing methods. Varied combinations of metallic and fibre-based structures (GRP-/ CFRP components) presuppose convenient joining methods.In this context, the objective of this research project is the development of an innovative joining method for combining sheet metals with CFRP structures. The target of the proposed project is motivated by the requirement for such methods to prevent any damage of the used textile fibre structures during the joining process. Based on the semi-solid forming technology, the new joining process is to be developed to create a material integrated bond between fibres and metallic components.Basic experiments, described in this research proposal, have already shown the technical feasibility of this new type of joining technique. The research work to be carried out comprises the usage of different sheet alloys: The combinations steel-aluminium, aluminium-aluminium and steel-steel are to be joined reliable with internal carbon textiles. Subsequently, the quality of the produced hybrid structure is to be analysed by optical and mechanical examinations and, additionally, the reactions between the sheet metals or, respectively, between fibres and sheet metals have to be investigated.Furthermore, the new composite is to be numerically modelled by using the software ANSYS. Fluid dynamics and structure-mechanical processes are to be calculated by CFD and CSM codes. In this way, the infiltration of the rovings can be simulated. Based on these results, it should be possible to perform calculations of the composites´ strengths. In this way, the project is to provide evidence that the quality of manufactured connections and related to that the required process parameters can be calculated prior to the joining process.