Colin Gerstenberger

High load-bearing multi-material-joints of metal sheets and composites by incremental in-situ forming processes

Thermo-mechanically flow-formed joints (FDJ) are an appropriate joining technology to realize high load-bearing multi-material-joints between fiber reinforced thermoplastics and sheet metals, without additional joining components. As in the automotive industry new vehicle and lightweight designs with one-sided accessibility joints are required, the technology which so far requires a two-sided accessibility of the joint, is examined for the ability to be performed with one-sided accessibility. The main part of the paper are therefore experimental studies on the one-sided manufacturing of FDJ-joints without an additional forming tool and their examination with head pull test and tension shear test according to DIN EN ISO 14272 and DIN EN ISO 14273. In this context, a tool and an experimental setup were designed to provide a corresponding joint production of a material combination of continuous glass fiber reinforced polypropylene (Plytron) and an aluminum alloy (EN AW-6082 T6). In the experiment, the novel ...

Combined Injection Molding Technology for Dynamically Stressed Multi-Material Coupling Elements

The manufacturing of high load components in automotive and mechanical engineering demands for an increased usage of combined plastics processing procedures. In practice, full plastic hybrid components are produced in a series of individual processes such as thermoforming or injection molding. The constructive implementation has often only material-substituting character wherein the high potential for lightweight anisotropic fiber composites is exploited only to a limited extent. Based on the application of a coupling brace in a vehicle, a new component design for function-integrated interface elements is enabled by an integrated injection molding technology. The targeted transfer of high local stresses by load-bearing insert elements regarding contoured metal sheets or Fiber Reinforced Thermoplastic Composites (TP-FRC) semi-finished products with endless fiber reinforcement enables efficient dimensioning of components. This fusion of technologies to a Multi Material Design (MMD) form the basis for novel weight-optimized, as well as cost-effective applications and lead to a high bending stiffness and high strength of structures. The composite strength of MMD components is increased by a variation and optimization of the thermoplastic/TP-FRC respectively thermoplastic/metal-interfaces. This objective will be achieved by highly efficient and integrated process flows and by the new entire construction of the component.