SPP 1712:  Intrinsic Hybridcomposites for Lightweight Construction Structures - Basics of Manufacturing, Characterisation and Mechanical Design

• Subject Area: Mechanical and Industrial Engineering ; Materials Science and Engineering
• Term: from 2014 to 2021
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 237091934

Nowadays, the use of lightweight construction structures offers the opportunity to significantly reduce weight. In designing these lightweight construction structures, a wide range of requirements have to be considered depending on the type of application. The complete substitution of a material in order to use the full potential of the lightweight construction does not always lead to the desired result. Thus, the ideal overall structure consists of a hybrid material combination, the so-called multi-material design. Consequently, the approach of hybridising structural components is becoming increasingly prominent and can be performed basically by applying two different methods. The joining of hybrid composites by post moulding assembly, such as adhesive bonding or screwing, has already become a well-established approach.
However, these methods do not fully exploit the potential of lightweight construction. A promising alternative approach is the production of hybrid composites in a single-stage process. Here, the different materials are joined by primary shaping or forming processes without a subsequent joining process. The terminology for describing these processes has not yet been standardised. In this Priority Programme, the term "intrinsic hybrid" shall thus refer to this process according to the following definition: An intrinsic hybrid is an integral component whose various materials are connected by primary shaping or forming of the metallic or continuous fibre-reinforced component. Thus, there is no need for a subsequent joining process.
Key aspects of this this Priority Programme are resource-efficient manufacturing as well as characterisation and design of load-optimised, intrinsic hybrid components for lightweight load-bearing structures. In this context, disciplines such as mechanics, material science and production collaborate in an integral approach.

• DFG Programme: Priority Programmes

Projects

• Basic research on intrinsically produced FRP-/metal-composites - from embedded inserts to load-bearing hybrid structures (Applicants Fleischer, Jürgen ;  Henning, Frank ;  Weidenmann, Kay A. )
• Coordination Funds (Applicant Fleischer, Jürgen )
• Development of the theoretical and technological fundamentals for intrinsic thermoplastic composite/metal hollow profiles with load-adapted cross-scale form fit (Applicants Gude, Maik ;  Kästner, Markus ;  Müller, Roland )
• Effects, Detection and Prediction of Defects in Hybrid Composite Parts for Metal/CFRP-Lightweight Structural Structures Suitable to Large-Volume-Production (Applicants Herrmann, Hans-Georg ;  Lanza, Gisela ;  Stommel, Markus )
• Intrinsic hybrid composites for crash-relevant structural parts processed by forming (Applicants Drossel, Welf-Guntram ;  Ihlemann, Jörn ;  Lampke, Thomas ;  Wagner, Martin Franz-Xaver )
• Intrinsic production of hybrid components utilizing a modified RTM-process (Applicants Mahnken, Rolf ;  Meschut, Gerson ;  Schaper, Mirko ;  Tröster, Thomas )
• Multilayer-Inserts - Intrinsic hybrid materials for force transmission into thin-walled high performance CFRP-structures (Applicants Denkena, Berend ;  Horst, Peter ;  Meiners, Dieter )
• Residual Stressesin intrinsic hybrid laminates, detection, modification and consideration in manufacturing and the numeric damage modeling (Applicant Sinapius, Michael )
• Stress adapted design of load application elements for hybrid light-weight shafts manufactured by centrifugal process (Applicant Fleischer, Jürgen )

• Spokesperson: Professor Dr.-Ing. Jürgen Fleischer