A hybrid casting process for the manufacturing of intrinsic CFRPaluminum compounds

• Applicants: Professor Dr.-Ing. Matthias Busse; Professor Dr.-Ing. Axel Herrmann; Dr. Katharina Koschek
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing ; Materials in Sintering Processes and Generative Manufacturing Processes
• Term: from 2015 to 2022
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 281570803

The manufacturing process of high pressure die casting offers a series mass production with near net shape design of light metal components. The lightweight construction material CFRP (carbon fiber reinforced plastic) is well established as a high-performance material for the production of highly durable and ultra-lightweight components. The combination of the two materials aluminum and CFRP is currently the focus of engineers to create lightweight structures. The specified aim of the first funding period was to combine the materials aluminum and thermoplastic CFRP into an intrinsic hybrid composite within a single, original manufacturing step. This aim has been successful achieved. The results show that it is not just possible to combine CFRP with aluminum using high pressure die casting. The tensile shear tests achieved a joint strength approximately in the range of current single lap adhesive bonds. Based on the results so far, new deepening question for the upcoming project phase could be defined. 1. Detailed characterization of the interface and development of process boundaries for the production of hybrid composite2. Investigation of the influence of different heat treatments and development of a heat treatment method tailored to the hybrid composite3. Optimization of the hybrid composite and development of design recommendationsThe results of the bond strength, which are in the range of structural adhesives, show that PEEK behaves similar to an adhesive. Further investigations in this area, including chemical analysis, could help to contribute that this novel technology could find application in other areas of joining technology as well.

• DFG Programme: Research Grants