FOR 1224: CFRP-Aluminium Transition Structures in Lightweight Design

为了使构件性能适应局部要求，FRP（纤维增强塑料）-金属组合结构构件在轻量化设计中的应用越来越多。新颖的连接概念是实现重量和工艺优化所必需的。该研究单位的目标是开发铝和碳纤维增强塑料（CFRP）之间的整体过渡结构，从而实现精益和重量最小化的设计，减少生产步骤以及优化负载应用方面的优势。该研究股于2010年夏季开始工作。五个项目合作伙伴中的三个正在利用其核心竞争力开发新型关节并进行生产。因此使用了纺织、焊接和铸造技术。其他合作伙伴通过实验和数值调查来支持开发过程，以验证和增强解决方案。所有员工都进行了全面调查，并开始进行初步测试，以检查所有概念的可行性。对静力作用下cfrp -铝过渡结构解耦连接区断裂行为进行了概念选择、生产工艺的首次尝试、有限元建模和分析。在这种情况下，过渡结构是由钛丝环实现的。线圈通过纺织技术连接到碳纤维上，通过激光束焊接或铸造技术连接到铝板上。获得的技术经验为确定所有概念的跨学科规范提供了基础。由于范围的巨大自由以及各种工艺和材料参数，设计方案将在项目期间逐步完善。在第一个项目中，可以获得连接的阶段结果，这些结果针对静载荷应用进行了优化，此外还有连接的制造概念和耐腐蚀性研究。潜在的第二阶段的进一步练习是为不同的应用开发选定的解决方案，并优化动态负载的设计。

To adapt component properties to local requirements the application of combined FRP (fibre reinforced plastics)-metal structural components in lightweight design is increasing. Novel joining concepts are necessary for the weight and process optimised realisation. The Research Unit's objective is to develop integral transition structures between aluminium and CFRP (carbon fibre reinforced plastic), which lead to a lean and weight-minimised design and to a reduction of production steps as well as to advantages concerning optimised load application. The Research Unit started work in summer 2010. Three of the five project partners are developing novel types of joints using their core competence and produce them as well. Thereby textile, welding and casting technologies are used. The other partners support the development process with experimental and numerical investigation for validation and enhancement of the solutions. All associates undertook comprehensive investigations and started preliminary tests to check feasibility of all concepts. Selecting of one concept, first attempts production processes, FE-modelling and concerning fracture behaviour of decoupled connection zones in CFRP-aluminium transition structure under static load application were made. In this case, the transition structure is realised by titanium wire loops. The wire loops are connected to the carbon fibre by textile technologies and to the aluminium sheet by laser beam welding or alternatively by casting technologies. The gained technical experiences provide a basis for determining the interdisciplinary specifications for all concepts. Due to the immense freedom of scope and a variety of process and material parameters, design solutions will be gradually improved during the project. In the first project, phase results for connections are available, which are optimised for static load application, furthermore manufacturing concepts for the joints and investigations concerning corrosion resistance. Further exercises for a potential second phase are to develop selected solutions for different applications and the optimisation of the design for dynamic loads.