Energy-efficient manufacturing and mechanism-based characterization of the corrosion fatigue behavior of laser-structured hybrid composites

该研究项目的目的是通过解决移动性领域的问题，开发和表征用于高载荷汽车车身部件的固有粘结和耐腐蚀的CFRP/Al 6082混杂复合材料。现代汽车是多材料设计的，尽管混杂复合材料的制造需要许多主要是人工操作的步骤，以及在工艺、高压蒸压工艺和加工过程中防止污染等方面的高标准，导致成本较高。此外，必须考虑结构元件中的内应力和单个组件的电化学隔离，以避免碳纤维与金属(例如CARALL)之间的接触腐蚀。在研究项目中，除了通过轻量化结构提高面向应用的效率外，混合动力部件的制造工艺以及特性将进行能效设计。因此，纤维增强塑料与金属构件之间的本征材料粘结以及最终结构件的成形将一步完成，减少了所需的工艺步骤和时间。关于疲劳和腐蚀行为，将通过仪表化腐蚀疲劳试验来研究金属连接表面激光组织的有效性。借助变形行为的力学表征，将建立关于老化和损伤过程的基本知识。在合作前期工作的基础上，选择Al 6082-T6合金与碳纤维(纤维类型：SGL C30 T050 342Epy)和环氧树脂E201(SGL基团)的组合作为模型体系。该项目结构涉及三个项目合作伙伴在混杂复合材料制造(LIA)、连接工艺和界面分析(DLR)以及腐蚀疲劳行为(WPT)测量和测试方法方面的专业知识和研究。只有通过跨学科交流成果和数据，才能实现该项目的目标。

The aim of the research project by addressing the mobility sector is the development and characterization of intrinsic bonded and corrosion-resistant CFRP/Al 6082-hybrid composites for the application in higher loaded car body parts. Modern cars are multimaterial designs nowadays, although the manufacturing of hybrid composites requires a lot of mostly manual work steps and high standards concerning methodology, autoclave processing and prevention of contamination during processing, resulting in high costs. Furthermore, internal stresses in the structural element and the electrochemical isolation of the individual components to avoid contact corrosion between carbon fibers and metal (e.g. CARALL) must be considered. In the research project, besides this applicationoriented efficiency enhancement through lightweight construction, the manufacturing process of the hybrid components as well as thecharacterization will be designed energy-efficiently. Therefore, the intrinsic material bond between fiber-reinforced plastic and metallic components as well as forming of the final structural element will be realized in one work step, to reduce needed process steps and time. Concerning fatigue and corrosion behavior, the effectiveness of laser structuring of the metallic joining surfaces will be investigated over instrumented corrosion fatigue tests. With the help of mechanismbased characterization of the deformation behavior, basic knowledge about aging and damage processes will be build up. On the basis of cooperative pre-work the combination of the alloy Al 6082-T6 with carbon fibers (fiber type: SGL C30 T050 342 EPY) and epoxy resin E201 (SGL Group) was chosen as model system. The project structure implicates the expertise and research of the three Project partners concerning manufacturing of hybrid composites (LiA), joining processes and interface analysis (DLR) as well as measurement and test methodology with regard to the corrosion fatigue behavior (WPT). The aim of the project can only be realized by the interdisciplinary exchange of results and data.