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ProVorPlus

Functionally integrated process technology for the prefabrication and component production of FRP metal hybrids

Motivation and problem

In order to increase the economic potential of FRP-based lightweight construction, the fabrication of components with a component-integrated hybridization is sought. Here different materials with different characteristics are combined into one component, by which a functionalization (mechanical, thermal, acoustical and electrical) of the individual materials is enabled.

The approach of a component-integrated hybridization involves the necessity to develop appropriate production technologies which enable complex components (e.g. for the load path-optimized construction) to be produced in an automated and efficient way in a continuous process chain. Due to the manufacturing technologies that are mostly constructed specifically to materials and components, the production of shell-shaped components in the multi-material-mix with todays‘ technologies regarding procedures, machines and tools is not manageable in an ecomic way. Therefore, process chains are needed that go beyond the concepts used so far with their material-oriented machine concepts and secure a high degree of automation.

Project goals and contents

The joint project aims at the provision of a production technology and the construction of a continuous process chain capable for mass-production of shell-shaped, fiber-reinforced thermoplast-metal-hybrid structure components. Load path-optimized and functionally integrated components shall be produced through the use of pre-assembled multi-material preforms (metal and FRP). Thus, components shall be produced in one shot without further joining operations in a combined forming/casting process. The realization of this process chain is achieved by the manufacturing of a demonstration component in the Open Hybrid LabFactory.

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