In-situ-Prozesse für hybride Strukturbauteile in Leichtbauweise

The aim of this work is to develop an innovative manufacturing process for highly functionalized structural components using PFH technology. The IHU/injection molding process is fundamentally analyzed specifically for the processing of fiber-reinforced plastic (FRP) profiles, and the individual process stages are modified through the use of suitable process media and parameter settings. With the help of extensive analytical and numerical calculations, as well as the successful implementation of a novel temperature control concept, it is now possible to shape FRP profiles without the use of barrier layers, close to the final contour, and reproducibly in serial cycle times. Additionally, this allows for functionalization through injection molding and a comprehensive mastery of the hybrid process. A comparison of the bond strengths with hybrid reference components demonstrates that by using a material-bonded connection, time- and cost-intensive pre-treatments can be saved while achieving higher bonding qualities. To equip the PFH structural component with assembly-compatible connection interfaces to materials of different types in multimaterial structures, a specially developed process-complementary in-situ integration method is employed. Finally, a general methodological approach for technological transfer and adaptation is systematically broken down, allowing for the traceability of the individual development paths.