A hybrid casting process for the manufacturing of intrinsic CFRPaluminum compounds

高压压铸的制造工艺为轻金属零件的近净形设计提供了批量生产的途径。轻质建筑材料CFRP（碳纤维增强塑料）是一种高性能材料，用于生产高耐用性和超轻质部件。铝和CFRP这两种材料的结合是目前工程师们创造轻质结构的重点。第一个资助期的具体目标是在单一的原始制造步骤中将铝和热塑性碳纤维增强塑料材料结合成固有的混合复合材料。这一目标已成功实现。结果表明，采用高压压铸将CFRP与铝复合是不可能的。拉伸剪切试验获得的接头强度大致在当前单搭接粘合剂的范围内。根据目前的结果，可以为即将到来的项目阶段定义新的深化问题。1. 混合复合材料生产界面的详细表征和工艺边界的发展2。研究了不同热处理方式对复合材料性能的影响，开发了适合复合材料的热处理方法。混合复合材料的优化和设计建议的制定结合强度的结果，在结构粘合剂的范围内，PEEK的行为类似于粘合剂。在这一领域的进一步研究，包括化学分析，将有助于促进这种新技术在其他连接技术领域的应用。

The manufacturing process of high pressure die casting offers a series mass production with near net shape design of light metal components. The lightweight construction material CFRP (carbon fiber reinforced plastic) is well established as a high-performance material for the production of highly durable and ultra-lightweight components. The combination of the two materials aluminum and CFRP is currently the focus of engineers to create lightweight structures. The specified aim of the first funding period was to combine the materials aluminum and thermoplastic CFRP into an intrinsic hybrid composite within a single, original manufacturing step. This aim has been successful achieved. The results show that it is not just possible to combine CFRP with aluminum using high pressure die casting. The tensile shear tests achieved a joint strength approximately in the range of current single lap adhesive bonds. Based on the results so far, new deepening question for the upcoming project phase could be defined. 1. Detailed characterization of the interface and development of process boundaries for the production of hybrid composite2. Investigation of the influence of different heat treatments and development of a heat treatment method tailored to the hybrid composite3. Optimization of the hybrid composite and development of design recommendationsThe results of the bond strength, which are in the range of structural adhesives, show that PEEK behaves similar to an adhesive. Further investigations in this area, including chemical analysis, could help to contribute that this novel technology could find application in other areas of joining technology as well.