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Intrinsic manufacture of hollow thermoplastic composite/metal structures

Intrinsische Fertigung von Thermoplastverbund-Metall-Hohlstrukturen
: Barfuß, Daniel; Grützner, Raik; Garthaus, Christian; Gude, Maik; Müller, Roland; Landgrebe, Dirk


Chinesta, F. ; American Institute of Physics -AIP-, New York:
19th International ESAFORM Conference on Material Forming 2016. Proceedings : 27-29 April 2016, Nantes, France
Woodbury, N.Y.: AIP, 2016 (AIP Conference Proceedings 1769)
ISBN: 978-0-7354-1427-3
Art. 170024, 6 pp.
International Conference on Material Forming (ESAFORM) <19, 2016, Nantes>
Conference Paper
Fraunhofer IWU ()
Intrinsic Hybrid; thermoplastic composite profile structures; metallic load introduction; multi scale form closure; integral blow moulding process; hydroforming

In contrast to common and classical joining technologies for composite/metal hybrid structures such as bonding and riveting, profile and contour joints offer a promising potential for novel lightweight hybrid structures. First and foremost, joining systems with a form closure function enable to pass very high loads into rod- and tube-shaped fibre reinforced structures and achieve high degrees of material utilization for the composite part. This paper demonstrates the theoretical and technological principals for a resource efficient design and production of highly loaded thermoplastic composite profile structures with integrated metallic load introduction elements and a multi scale form closure. The hybrid structures are produced in an integral blow moulding process in which a braided tape-preform is simultaneously consolidated and formed into the metallic load introduction element. These metallic load introduction elements are manufactured in a two-stage process of external and internal hydroforming, after forming simulations have assured process stability for consistent quality.