Joining of metal and fibre components based on the semi-solid forming process

• Applicant: Professor Dr.-Ing. Mathias Liewald
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: from 2015 to 2018
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 271949384

The trend towards lightweight construction in automotive engineering contributes significantly to environment protection by reducing pollutant emissions and by conserving resources. However, this development causes additional effort and higher expense in vehicle manufacturing, because new materials or, respectively, new material combinations require adapted production and processing methods. Varied combinations of metallic and fibre-based structures (GRP-/ CFRP components) presuppose convenient joining methods.In this context, the objective of this research project is the development of an innovative joining method for combining sheet metals with CFRP structures. The target of the proposed project is motivated by the requirement for such methods to prevent any damage of the used textile fibre structures during the joining process. Based on the semi-solid forming technology, the new joining process is to be developed to create a material integrated bond between fibres and metallic components.Basic experiments, described in this research proposal, have already shown the technical feasibility of this new type of joining technique. The research work to be carried out comprises the usage of different sheet alloys: The combinations steel-aluminium, aluminium-aluminium and steel-steel are to be joined reliable with internal carbon textiles. Subsequently, the quality of the produced hybrid structure is to be analysed by optical and mechanical examinations and, additionally, the reactions between the sheet metals or, respectively, between fibres and sheet metals have to be investigated.Furthermore, the new composite is to be numerically modelled by using the software ANSYS. Fluid dynamics and structure-mechanical processes are to be calculated by CFD and CSM codes. In this way, the infiltration of the rovings can be simulated. Based on these results, it should be possible to perform calculations of the composites´ strengths. In this way, the project is to provide evidence that the quality of manufactured connections and related to that the required process parameters can be calculated prior to the joining process.

• DFG Programme: Research Grants