Multi-scale structuring for thermoplastic-metal contour joints of hollow profiles

Barfuss, Daniel; Grützner, Raik; Hirsch, Franz; Gude, Μaik; Müller, Roland; Kästner, Markus

doi:10.1007/s11740-018-0800-9

Cited by 10 publications

(7 citation statements)

References 15 publications

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“…According to the current state of the art, hollow structures made of FRP for drive shafts or tie rods are produced by winding [16], pultrusion [11] or blow molding [1]. One variant of the winding process is wet filament winding where a roving is drawn through a thermoplastic matrix bath and wound onto a heated core.…”

Section: State Of the Artmentioning

confidence: 99%

“…The matrix is then injected into the cavity between blow hose and tool form. If the mold is heated, blow molding can also be applied for thermoplastic materials [1]. Impregnation processes such as resin transfer molding (RTM) or vacuum assisted transfer molding (VARTM) can likewise be used.…”

Section: State Of the Artmentioning

confidence: 99%

“…In order to attach the hollow FRP structures to the remaining system or install bearings and gearwheels, metallic elements are necessary. Established technologies for joining metallic load introduction elements with hollow FRP structures are interference fit [18], adhesive bonding [9], bolt connections, pin connections [19], form fit [1,17,21] or joints created by friction locking [6].…”

Section: State Of the Artmentioning

confidence: 99%

See 2 more Smart Citations

Production and Tensile Testing of Rotationally Molded Hybrid Composite Tie Rods

Fleischer¹,

Coutandin²,

Nieschlag³

2020

SAMPE 2020 | Virtual Series

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An innovative production processes for manufacturing rotationally symmetric FRP-metal components, such as drive shafts or tie rods, is the rotational molding process. In the course of this process, a dry fiber preform and metallic load-introduction elements are inserted into a two-piece mold and subsequently clamped into a spindle. The matrix is injected directly into the rotating mold. Due to the arising centrifugal forces, the preform is impregnated and the component cures under rotation. In comparison to conventional joining processes, such as adhesive bonding or bolt connections, the metallic components as well as the FRP part are intrinsically joined during the forming process. A downstream joining process is not required. The joint is based either on the adhesive property of the matrix system or on a form-fit geometry with undercuts. The paper addresses the production and tensile testing of tie rods. Different rod geometries and different surface treatments, including sandblasting, knurling, and arc spraying, are compared and evaluated.

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Section: State Of the Artmentioning

confidence: 99%

Section: State Of the Artmentioning

confidence: 99%

Section: State Of the Artmentioning

confidence: 99%

See 1 more Smart Citation

Production and Tensile Testing of Rotationally Molded Hybrid Composite Tie Rods

Fleischer¹,

Coutandin²,

Nieschlag³

2020

SAMPE 2020 | Virtual Series

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“…In most of the recent works [ 19 , 20 , 21 ], the hybrid-joint was manufactured by adhesives, screws or pins. Hence, direct contact prevailed between the metal and the CFRP constituent, resulting in a mechanical gradient at the interface.…”

Section: Introductionmentioning

confidence: 99%

Using Quantitative Passive Thermography and Modified Paris-Law for Probabilistic Calculation of the Fatigue Damage Development in a CFRP-Aluminum Hybrid Joint

Summa

Herrmann

2021

Polymers

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Although metal to Carbon-fiber-reinforced-polymer (CFRP) hybrid-joints possess a high lightweight construction potential, their extensive application has to deal with interfacial stress concentrations promoting fatigue damage. Furthermore, the underlying damage processes and their influencing factors are still not completely understood. Besides interfacial property-gradients, generic shapes counteract a precise determination of local stresses or strains, respectively. Hence, new methods are required that combine non-destructive testing and fracture mechanics to account for the fatigue damage. In this work, data of mechanical fatigue testing of an aluminum-CFRP hybrid-structure is presented by means of the dynamic stiffness and the mechanical hysteresis. Additionally, in situ passive thermography allows for capturing the heat development due to delamination growth. Correlating the obtained data implies that faster delamination growth coincides with higher amplitude values of lock-in thermography and higher mechanical hysteresis. Supported by this observation, a model is formulated to calculate the local dissipation per loading cycle. Further integration into a Paris-law like formulation results in a calculation model to account for the mode-I fatigue delamination growth. Additional validation of the model parameters shows good agreement with the experimental data.

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“…Conventional concepts like screw connections [1] or rivet joints [2,3] often induce undesired pre-damage within the composite, while the integration of additional adhesives increases the complexity of the manufacturing process [4]. Interlocking non-destructive approaches represent a suitable alternative [5][6][7], where the connection is created during a hybridization step. All mentioned approaches exhibit load-bearing interfaces, where failure typically initializes.…”

Section: Introductionmentioning

confidence: 99%

Modeling and simulation of interface failure in metal-composite hybrids

Hirsch

Natkowski²,

Kästner³

2021

Composites Science and Technology

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The application of hybrid composites in lightweight engineering enables the combination of material-specific advantages of fiber-reinforced polymers and classical metals. The interface between the connected materials is of particular interest since failure often initializes in the bonding zone. In this contribution the connection of an aluminum component and a glass fiber-reinforced epoxy is considered on the microscale. The constitutive modeling accounts for adhesive failure of the local interfaces and cohesive failure of the bulk material. Interface failure is represented by cohesive zone models, while the behavior of the polymer is described by an elastic-plastic damage model. A gradientenhanced formulation is applied to avoid the well-known mesh dependency of local continuum damage models. The application of numerical homogenization schemes allows for the prediction of effective traction-separation relations. Therefore, the influence of the local interface strength and geometry of random rough interfaces on the macroscopical properties is investigated in a numerical study. There is a positive effect of an increased roughness on the effective joint behavior.

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Multi-scale structuring for thermoplastic-metal contour joints of hollow profiles

Cited by 10 publications

References 15 publications

Production and Tensile Testing of Rotationally Molded Hybrid Composite Tie Rods

Production and Tensile Testing of Rotationally Molded Hybrid Composite Tie Rods

Using Quantitative Passive Thermography and Modified Paris-Law for Probabilistic Calculation of the Fatigue Damage Development in a CFRP-Aluminum Hybrid Joint

Modeling and simulation of interface failure in metal-composite hybrids

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