Design and intrinsic processing of a hybrid CFR-TP contour joint with a multi-scale structured load introduction element

In contrast to classical joining technologies for composite/metal hybrid structures like bonding and riveting contour joints prove to be a valuable alternative in terms of manufacturing efficiency and mechanical performance. This paper gives an overview of the design and the intrinsic processing technology of carbon fibre reinforced polyamide 6 with a multi-scale structured aluminium load introduction element. The presented approach combines a high pressure formed metal load introduction elements with an intrinsic bladder assisted blow moulded and braided fibre reinforced thermoplastic tape preform. This enables an industrial scale production of hollow hybrid composite structures with no need of post-processing operations. Design guidelines for principles of transferring high loads by multi-scale structured load introduction elements into composite profile structures are given. Further, the process parameters time, moulding pressure and process temperature are analysed and show a significant effect on the moulding quality of the part. An approach to manufacture a circumferential reinforcing bandage is presented. Additional investigations addressing the electrochemical compatibility of the joining partners are conducted and processing suitable surface treatment methods to minimize corrosion damage of the aluminium load introduction element are determined.