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Multi-scale structuring for thermoplastic-metal contour joints of hollow profiles

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Abstract

In contrast to common and classical joining technologies for composite/metal hybrid structures such as bonding and riveting, profile and contour joints offer a promising potential for novel lightweight hybrid structures. Contour joints with form locking elements on multiple scale levels enable to pass very high loads into rod- and tube-shaped fibre reinforced structures and promise high degrees of material utilization for the composite part. This paper demonstrates the advantage of multi-scale structured load introduction elements. First the intrinsic manufacturing process, whereas the thermoplastic tape braided preform is simultaneously consolidated and formed into the metallic load introduction element is shown. Numerical investigations on the macro- and generic microscale demonstrate the potential to trigger cohesive or adhesive failure by appropriate designed form locking elements. The extensive experimental investigation of meso-, macro- or combined-structured tubular specimen shows the beneficial effect of multi-scale structuring to increase the joining strength. Concluding advises for the contour joints’ design are given.

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Acknowledgements

The authors gratefully acknowledge the funding of this work by the German Research Foundation, DFG, within the priority program 1712: Intrinsic hybrid composites for lightweight structures—basics of manufacturing, characterization and design.

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Authors and Affiliations

  1. Institute of Lightweight Engineering and Polymer Technology, Technische Universität Dresden, Holbeinstr. 3, 01307, Dresden, Germany

    Daniel Barfuss & Maik Gude

  2. Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU, Reichenhainer Straße 88, 09126, Chemnitz, Germany

    Raik Grützner & Roland Müller

  3. Institute of Solid Mechanics, Technische Universität Dresden, George-Bähr-Str. 3c, 01602, Dresden, Germany

    Franz Hirsch & Markus Kästner

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  1. Daniel Barfuss
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  2. Raik Grützner
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  3. Franz Hirsch
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  4. Maik Gude
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  5. Roland Müller
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  6. Markus Kästner
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Correspondence to Daniel Barfuss.

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Barfuss, D., Grützner, R., Hirsch, F. et al. Multi-scale structuring for thermoplastic-metal contour joints of hollow profiles. Prod. Eng. Res. Devel. 12, 229–238 (2018). https://doi.org/10.1007/s11740-018-0800-9

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  • DOI: https://doi.org/10.1007/s11740-018-0800-9

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