Title: Fast and efficient automotive hybrid part manufacturing process using polyurethane-based prepregs

Authors: Zuhal Tuncay; Christina Cron; Marina-Elena Schmidt; Simon Poehler; Bamned Sanitther; Thomas Troester

Addresses: Evonik Resource Efficiency, Paul-Baumann-Straße 1, 45772 Marl, Germany ' Evonik Resource Efficiency, Paul-Baumann-Straße 1, 45772 Marl, Germany ' Evonik Resource Efficiency, Paul-Baumann-Straße 1, 45772 Marl, Germany ' Chair for Automotive Lightweight Design, University of Paderborn, Pohlweg 47-49, 33098 Paderborn, Germany ' Chair for Automotive Lightweight Design, University of Paderborn, Pohlweg 47-49, 33098 Paderborn, Germany ' Chair for Automotive Lightweight Design, University of Paderborn, Pohlweg 47-49, 33098 Paderborn, Germany

Abstract: A polyurethane-based prepreg with high metal adhesion is developed which enables a fast and efficient process route towards metal FRP hybrid parts. Forming of metal and FRP is achieved in a single step due to thermoplastic processing of the thermoset matrix. Cycle times can be reduced to below one minute for body-in-white parts since the time-consuming post curing step can be integrated into the cathodic dip coating process. The final demonstrator parts exhibit high bonding strengths between metal and FRP without the need for adhesives or metal pre-treatment.

Keywords: lightweight automotive design; multi-material approach; hybrid part; local patch reinforcement; carbon fibre composite; polyurethane prepreg; prepreg pressing; hat section; lap shear strength.

DOI: 10.1504/IJAUTOC.2018.094873

International Journal of Automotive Composites, 2018 Vol.4 No.1, pp.71 - 85

Received: 11 Dec 2017
Accepted: 20 Apr 2018
Published online: 25 Sep 2018 *

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