Customised metal/composite hybrids for automotive applications

The design principle of hybrid construction allows the manufacturing of weight-optimized structures with high stiffness and resistance that meet the increasing demands for energy-efficient production processes and components with high power density. In the automotive industry, this trend is particularly strong. Especially the use of fiber reinforced thermoplastics offers advantages for automotive components, due to its good specific characteristics and its suitability for mass production. In conjunction with traditional isotropic materials such as steel or aluminum heavy-duty lightweight structures can be produced, whose properties can be specifically adapted to the given component requirements. The aim of the present article is the development of innovative hybrid laminates with low residual stresses, made of steel sheets/foils and glass or carbon fiber reinforced thermoplastics. To increase the interlaminar shear strength (ILSS) an optimization of the specific interfaces was carried out by examining the influence of several pre-operations like sanding, cleaning with organic solvents and applying primer systems. Based on these findings optimized compound samples were prepared and tested under realistic CDP conditions to determine the influence on the ILSS.