High load-bearing multi-material-joints of metal sheets and composites by incremental in-situ forming processes

摘要

Thermo-mechanically flow-formed joints (FDJ) are an appropriate joining technology to realize high load-bearing multi-material-joints between fiber reinforced thermoplastics and sheet metals, without additional joining components. As in the automotive industry new vehicle and lightweight designs with one-sided accessibility joints are required, the technology which so far requires a two-sided accessibility of the joint, is examined for the ability to be performed with one-sided accessibility. The main part of the paper are therefore experimental studies on the one-sided manufacturing of FDJ-joints without an additional forming tool and their examination with head pull test and tension shear test according to DIN EN ISO 14272 and DIN EN ISO 14273. In this context, a tool and an experimental setup were designed to provide a corresponding joint production of a material combination of continuous glass fiber reinforced polypropylene (Plytron) and an aluminum alloy (EN AW-6082 T6). In the experiment, the novel joints bear maximum forces of 291 N in the head pull test and 708 N in the tension shear test.