Production of a Metal/Plastic Hybrid Structure via Impact Extrusion

用于生产高性能部件的不同材料的组合允许广泛的功能和适用性。因此，金属和塑料在混合结构中的使用在过去几年中变得越来越重要，因为它们各自的互补特性可以在轻量化结构，声学阻尼等领域得到利用。然而，允许共同制造这两种材料的生产过程的数量是有限的。因此，金属-塑料混合材料的潜力尚未得到充分利用。本研究项目的范围是开发一种通过冲击挤压在一个生产步骤中加工金属和塑料的新方法。目前还不存在这样的程序。这一概念的一般可行性已在先前的实验研究中得到证明。该研究项目的第一步将是进一步探索该过程的各个方面，例如，聚合物相塑化的机械能输入及其在变形过程中的流动行为。由此推导出冲击挤压模具的设计。在迭代循环中，零件将根据其特性进行生产和分析。研究结果将用于进一步优化该过程，并确定其潜力和局限性。最后，利用优化后的工艺参数生产金属-塑料混合部件，并确定其重量比力学性能和阻尼特性。

The combination of different materials for the production of high performance parts allows for a broad range of functionality and applicability. Thus, the use of metals and plastics for hybrid structures has grown more and more important within the last years, as their respective complementary characteristics can be exploited in the fields of lightweight construction, acoustic damping and others. However, the number of production processes allowing for a common manufacturing of both materials is limited. Therefore, the potential of metal-plastic-hybrids is not yet fully used.The scope of this research project is to develop a new way to process metal and plastic in one single production step via impact extrusion. Such a process does not yet exist. The general feasibility of this concept has already been shown in a preceding experimental study. The first steps within this research project will be to further explore separate aspects of the process e.g. the input of mechanical energy for the plasticization of the polymer phase and its flow behavior during the deformation. From these results the design of the impact extrusion die will be deducted. In an iterative loop, parts will be produced and analyzed in regard to their properties. The findings will be used to further optimize the process and define its potentials and limitations. Finally, metal-plastic-hybrid parts will be produced with optimized process parameters and their weight specific mechanic properties and damping characteristics will be determined.