Design of multi-scale-structured Al-CF/PA6 contour joints

In contrast to common joining technologies for composite-metal hybrid structures such as bonding and riveting, contour joints offer promising potential in terms of manufacturing efficiency and mechanical performance. For composite structures, joining systems with positive locking elements enable to pass high loads and are capable to achieve high degrees of material utilisation. To enhance the performance of hybrids, a multi-scale structuring approach is sought. Aiming at high rate production, especially in automotive industry, an intrinsic manufacturing approach whereat the composite part is joined to the metallic part during its consolidation process has been developed. This paper demonstrates the intrinsic manufacturing principles of continuous fibre-reinforced thermoplastic hollow profiles with multi-scale-structured load introduction and mainly focuses on the development of a fibre appropriate design. Based on a design of experiment approach, numerical parameter studies for the optimisation of macro contour have been carried out to create a general design guideline.