Verfahrensentwicklung zur Herstellung von hybriden FVK/Stahl-Strukturen mittels eines neuartigen Blechverbindungselementes : Berichtszeitraum 01.05.2015 bis 31.08.2017

Abstract

The research project „Process Development for Manufacturing of Hybrid FRP-Steel Structures by Means of a Novel Sheet Joining Element“ addressed the investigation of applying the widespread technology of resistor element welding to joining two dissimilar materials (steel and fiber-reinforced thermoplastic). A base plate equipped with three or more joining pins worked as basic concept. The pins are meant to penetrate the locally molten thermoplastic thus working through the FRP material while leaving as majority of fibres intact. Sticking out of the back side of the FRP material, the pins were then welded to a steel component upon contact through conventional spot welding. Thereby, electric energy is induced through the head plate and the pins. The proposed joining elements can be manufactured in an industrial die-cutting and forming operation. However, the three required process steps (element manufacturing, FRP penetration and welding) constitute contrary target goals in terms of geometrical pin design and material selection. During the research project, each individual process was developed and eventually optimized in such a way that ensured a hybrid joint with sufficient strength. Therefore, element geometries were adapted continuously. In conclusion, the goals of the research project were so achieved.