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

汽车工程向轻量化方向发展的趋势，通过减少污染物排放和节约资源，为环境保护做出了重大贡献。然而，这种发展在汽车制造中造成了额外的工作量和更高的费用，因为新材料或新材料组合分别需要适应的生产和加工方法。金属和纤维基结构(GRP/CFRP构件)的不同组合为方便的连接方法提供了前提，本研究项目的目标是开发一种创新的将金属薄板与CFRP结构相结合的连接方法。拟议项目的目标是要求采用这种方法，以防止在连接过程中对旧纺织纤维结构造成任何损害。在半固态成形技术的基础上，将开发一种新的连接工艺，以在纤维和金属部件之间形成一种材料完整的结合。本研究方案中描述的基本实验已经证明了这种新型连接技术的技术可行性。将开展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纤维纺织品可靠地连接在一起。随后，将通过光学和力学检查来分析所生产的混杂结构的质量，此外，还必须研究金属板材之间或纤维与金属板材之间的反应。此外，还将使用软件Ansys对新的复合材料进行数值模拟。流体动力学和结构力学过程采用CFD和CSM程序进行计算。通过这种方法，可以模拟粗纱的渗透过程。基于这些结果，应该可以对复合材料的强度进行计算。通过这种方式，该项目将提供证据，证明制造的连接的质量和相关的，所需的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.