Abstract
The development of a new joining technology, which is used to manufacture high strength hybrid constructions with thermoplastic composites (FRP) and metals, is introduced. Similar to natural regulation effects at trees, fibers around the FRP joint become aligned along the lines of force and will not be destroyed by the joining process. This is achieved by the local utilization of the specific plastic flow properties of the FRT and metal component. Compared with usual joining methods—such as flow drill screws, blind and self-piercing rivets—noticeably higher tensile properties can be realized through the novel process management. The load-bearing capability increasing effect could be proved on hybrid joints with hot-dip galvanized steel HX420LAD and orthotropic glass—as well as carbon—fiber reinforced plastics. The results, which were determined in tensile-shear and cross-shear tests according to DIN EN ISO 14273 and DIN EN ISO 14272, are compared with holding loads of established joining techniques with similar joining point diameter and material combinations.
Highlights
The trend towards the use of lightweight materials is strong; it is being assumed that the proportion of fiber-reinforced thermoplastics (FRP) will continue to rise in the medium term
The realignment and the resulting length variation of the fiber reinforcement are described at the plasticized joining area by a geometric model of a unidirectional FRP ply, which considers the most deflected and therewith most stretched fiber at the edge of the joining point (Figure 6)
Towards conventional techniques the new load adjusted joining process occurs from the metal side and is supported by heat. This joining sequence in particular serves the FRP component, because fiber and interfiber fracture can be avoided at the joint
Summary
The trend towards the use of lightweight materials is strong; it is being assumed that the proportion of fiber-reinforced thermoplastics (FRP) will continue to rise in the medium term. The backgrounds to this are not the least requirements for reduction in CO2 emissions for fleet consumption. Manufacturing FRP/metal-hybrids can be realized by nonpositive (friction-based) as well as positive or firmly bonded joining approaches. They generally require several extra joining elements, which increase the weight of the assembly. For the first time the fusion and adaptation of both technologies allow tolerant and reproducible joining of both material systems within a short process time, according to design principles in nature
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