Hybrid Forming - A Method for Simultaneous Forming of High Strength Metal Sheet and Long Fiber Reinforced Plastic

Abstract

Fiber reinforced plastics (FRPs) are increasingly being used to reinforce the steel or aluminum automotive structure components. Currently, these multi-material applications are realized in general by a multi-stage manufacturing with considerable cost increase. To avoid this, a new hybrid forming method has been proposed and developed. It uses the half liquid FRP as a pressure media to hydro-form the sheet metals, form the reinforcement ribs of FRPs, and create the bonding between metal sheet and FRP in the same time and process step. In this work, the die sealing concepts for two test geometries could be successfully developed. The hybrid forming parameters (Temperature, pressure, speed etc.) are in a reasonable range and can be accepted by the industry. It could be approved that high strength steels with up to 800 MPa tensile strength could be hybrid formed successfully together with a LFT PA6 GF40 for a real car component. 20% weight reduction could be achieved.