Abstract
Multi-material-design (MMD) is commonly realized through the combination of thin sheet metal and fibre reinforced plastics (FRP). To maximize the high lightweight potential of the material groups within a multi-material system as good as possible, a material-adapted and particularly fibre adjusted joining technology must be applied. The present paper focuses on two novel joining technologies, the Flow Drill Joining (FDJ) method and Spin-Blind-Riveting (SBR), which were developed for joining heavy-duty metal/composite hybrids. Tests were carried out with material combinations which are significant for lightweight constructions such as aluminium (AA5083) and carbon fibre-reinforced polyamide in sheet thickness of 1.8 mm. The mechanical testing and manufacturing of those multi-material joints was investigated.
Highlights
Load-path adapted multi material design initiates significant mass reduction in automotive industry and contributes to resource savings
The present paper focuses on two novel joining technologies, the Flow Drill Joining (FDJ) method and Spin-Blind-Riveting (SBR), which were developed for joining heavy-duty metal/composite hybrids
This paper focuses on the qualification of the new flow-drill joining (FDJ) concept and the Spin-Blind-Riveting (SBR) concept – showing potentials and references for automotive application
Summary
Load-path adapted multi material design initiates significant mass reduction in automotive industry and contributes to resource savings. The combined use of metal sheets and fibre-reinforced plastic (FRP) offers a very high lightweight potential (Klein, 1997; Rosato, 2005; Goede et al, 2010) through all the material groups. The joining technology for thin-walled structural components, made of FRP and metal sheets, is considered to be extremely challenging. Mechanical methods such as screwing, blind and punch riveting as well as hybrid techniques are applicable (Simon, 2005) due to the strongly different thermo-mechanical behaviour and the divergent material composition and morphology. The fibres can be aligned along the force flux lines at the joint of the FRP component With these new technologies, it is possible to join different materials without the need of predrilling. A minimum preparation effort and less destruction of fibres can be guaranteed
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