Integral blow moulding for cycle time reduction of CFR-TP aluminium contour joint processing

Integral blow moulding (IBM) as a joining technology of carbon fibre reinforced thermoplastic (CFR-TP) hollow profiles with metallic load introduction elements enables significant cycle time reduction by shortening of the process chain. As the composite part is joined to the metallic part during its consolidation process subsequent joining steps are omitted. In combination with a multi-scale structured load introduction element its form closure function enables to pass very high loads and is capable to achieve high degrees of material utilization. This paper first shows the process set-up utilizing thermoplastic tape braided preforms and two-staged press and internal hydro formed load introduction elements. Second focuses on heating technologies and process optimization. Aiming at cycle time reduction convection and induction heating in regard to the resulting product quality is inspected by photo micrographs and computer tomographic scans. Concluding remarks give final recommendations for the process design in regard to the structural design.