Project Details
Projekt
Multi-functional high-performance profile systems in intrinsically manufactured fiber composite metal hybrid design (ProMi)
Subject Area
Joining and Separation Technology
Term
since 2022
Project identifier
Deutsche Forschungsgemeinschaft (DFG) - Project number 445506821
In contrast to conventional joining methods such as adhesive and riveting technologies, profile and contour connections, which have hardly been investigated for fiber composite structures to date, offer a promising starting point for novel lightweight structures in fiber-composite-metal design due to their material- and production-compatibility. These mainly form-fitting joining systems allow the introduction of highest loads in rod-shaped and tubular composite structures such as tie rods, pressure vessels and drive shafts. While the composite material is designed and dimensioned mainly with regard to the requirements of the composite tube area, the metallic load introduction element can be tailored to the composite’s fiber architecture by additive manufacturing technologies to further enhance the load bearing capability of the hybrid. Within the Priority Programme SPP 1712, currently, the technologies for the efficient intrinsic production of fiber-thermoplastic composite (FTV) hollow-profile structures are successfully explored and demonstrate the high technical and economic potential. General design guidelines for hollow profile structures based on engineering thermoplastics such as polyamide (PA) 6 with integrated metallic load introduction elements are given. Especially intrinsic manufacturing technologies, such as the "integral blow molding process" or the "thermoplastic centrifugal molding process" in combination with surface-structured metallic load introduction elements, can be utilized to efficiently manufacture large and medium lot sizes.The aim of the proposed project is the transfer of knowledge and technology from the SPP 1712 to pre-competitive research in industry. Based on the findings of the SPP 1712, the centrifugal and the integral blow molding process as well as the associated process and structural models are expanded in collaboration with the industry and then validated using exemplary wastewater pipelines and tension-compression rods from aviation. The specific project goals are on the one hand a practice-oriented process and component design modeling and on the other hand a technology extension for the intrinsic production of complex-shaped highly stressed profile systems based on the high-performance thermoplastic PolyEtherEtherKeton (PEEK).
DFG Programme
Research Grants (Transfer Project)
Application Partner
Boeing Deutschland GmbH; Diehl Aviation Gilching GmbH; Robert Hofmann GmbH; Teijin Carbon Europe GmbH; herone GmbH
