Title: Design of multi-scale-structured Al-CF/PA6 contour joints

Authors: Daniel Barfuss; Christian Garthaus; Maik Gude; Raik Grützner

Addresses: Technische Universität Dresden, Institute of Lightweight Engineering and Polymer Technology, ILK, Holbeinstr. 3, 01307 Dresden, Germany ' Technische Universität Dresden, Institute of Lightweight Engineering and Polymer Technology, ILK, Holbeinstr. 3, 01307 Dresden, Germany ' Technische Universität Dresden, Institute of Lightweight Engineering and Polymer Technology, ILK, Holbeinstr. 3, 01307 Dresden, Germany ' Fraunhofer-Institute for Machine Tools and Forming Technology IWU, Nöthnitzer Str. 44, Dresden, Germany

Abstract: In contrast to common joining technologies for composite-metal hybrid structures such as bonding and riveting, contour joints offer promising potential in terms of manufacturing efficiency and mechanical performance. For composite structures, joining systems with positive locking elements enable to pass high loads and are capable to achieve high degrees of material utilisation. To enhance the performance of hybrids, a multi-scale structuring approach is sought. Aiming at high rate production, especially in automotive industry, an intrinsic manufacturing approach whereat the composite part is joined to the metallic part during its consolidation process has been developed. This paper demonstrates the intrinsic manufacturing principles of continuous fibre-reinforced thermoplastic hollow profiles with multi-scale-structured load introduction and mainly focuses on the development of a fibre appropriate design. Based on a design of experiment approach, numerical parameter studies for the optimisation of macro contour have been carried out to create a general design guideline.

Keywords: contour joint; intrinsic hybrid; multi-scale; thermoplastic tape.

DOI: 10.1504/IJAUTOC.2016.084329

International Journal of Automotive Composites, 2016 Vol.2 No.3/4, pp.299 - 315

Received: 02 Sep 2016
Accepted: 07 Feb 2017

Published online: 26 May 2017 *

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