JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 35

By

structures

Hybrid structures for tailored structural automotive components
Protecting passengers and their comfort, reducing vehicle weight and minimizing production costs are important aspects when developing new automotive components and structures. These apply in particular to the development of crash-relevant structures. Moreover, to meet future climate protection regulations, the automotive industry needs to develop innovative and integral approaches for lightweight construction.

CHRISTIAN LAUTER, SCIENTIFIC ASSISTANT MEIKE FRANTZ, SCIENTIFIC ASSISTANT BERND SIEWERS, SCIENTIFIC ASSISTANT THOMAS TRÖSTER, CHAIR UNIVERSITY OF PADERBORN, CHAIR FOR AUTOMOTIVE LIGHTWEIGHT CONSTRUCTION (LIA)

Hybrid structures

about 30 minutes. An alternative process is the prepreg press technology where an uncured CFRP prepreg is directly formed into a sheet-metal structure. There are no limitations for the type of material used in the metallic component, so steels that can be hard-metal pressed can also be used. In this case, the epoxy resin of the prepreg also serves as an adhesive. After the forming process, the tool is kept closed about three to five minutes to
Fig. 1: Load-adjusted hybrid hat section: metallic pillar structure with local CFRP reinforcement

T

hree main trends are currently observed in lightweight automotive construction. First lightweight design can involve high-strength metal alloys, replacing metals with composites and combining different hybrid materials. Using high-strength metal alloys offers the opportunity to reduce the wall thickness of structures. However, once a critical minimum thickness is reached, designers can expect stability problems. The potential of high-strength materials for lightweight construction is thus limited. Replacing conventional construction materials with carbon-fibre-reinforced plastics (CFRP) allows considerable weight savings [1], [2]. This substitution is restricted to high-priced vehicles due to long cycle times and high material costs. Multi-material systems or hybrid structures consist of a combination of different materials that utilise the advantages of each material.

Structural components based on a multimaterial or hybrid design are a promising alternative. In this context, a combination of sheet-metal blanks with a local CFRP reinforcement is investigated. This design should allow manufacturers to produce safety-relevant vehicle components, such as b-pillars, at lower costs compared to a mere CFRP design [3]. The local CFRP reinforcement in sheet-metal structures offers a high weight-saving potential because the reinforcing patch can be applied only in highly loaded areas, while the reinforcing properties can be adjusted to special load cases [4] (Fig. 1). Locally applying the CFRP can reduce the wall thickness of steel parts. Furthermore, material costs can be effectively reduced compared to mere CFRP parts. An adequate component could be produced by separately forming the sheet metal part, manufacturing the CFRP reinforcement and bonding them with an adhesive. This combination results in comparatively long process chains as well as long cycle times, because the curing time of adhesives is

No69 November - December 2011 / jec composites magazine

35

Feature land transportation



JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011

Cover
Edito
Point of view - Umeco: focused on growth
Contents
Agenda of Events
COMPANY & BUSINESS
- In brief
- Australia - A continuous fibre tissue machine at Regina Glass Fibre
APPLICATIONS
- Marine - Signature marine projects and record-breaking super yacht
- Automotive - World’s first production-ready thermoplastic wheel rim
- Building & construction - A definite and technical success to help the fight against AIDS
MARKET
- China - The Chinese composite market: bright prospects
- CFRP - Wind surpasses aerospace as top user of advanced compositematerials
- Sustainability - Acting on sustainability for business value
FEATURE LAND TRANSPORTATION
- Raw material - Resin and gelcoat compliant with the new railway standard
- Prepreg - Phenolic prepreg is welcome aboard Bombardier’s class 379 Electrostar EMU passenger trains
- Sandwich construction - Rolling stock: weight reduction pays off
- CFRP - New carbon-fibre-reinforced composite for vehicle bodies and electric vehicles
- Design - Next generation composites – driving innovation in the ground transportation sector
- Structures - Hybrid structures for tailored structural automotive components
- Process - Composite reduces vehicle and sunroof weight and enables assembly and process innovations
RESEARCH & DEVELOPMENT
- Joining - Investigating the properties and failure mechanisms of a damage-tolerant 3D-reinforced joint for lightweight structures
- Bonding - 3D sandwich panel manufacturing with great properties as result
TECHNOLOGY & INNOVATIONS
- Corrosion - Glass fibre reinforcement type determines FRP corrosion performance
- Thermoplastics - The promise of fibrereinforced thermoplastics: low weight and recyclability
- Manufacturing - New mould manufacturing process
- Foam - A new product range for marine applications
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - Cover
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 2
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - Edito
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - Point of view - Umeco: focused on growth
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 5
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - Contents
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 7
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 8
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - COMPANY & BUSINESS
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - In brief
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Australia - A continuous fibre tissue machine at Regina Glass Fibre
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Marine - Signature marine projects and record-breaking super yacht
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 13
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Automotive - World’s first production-ready thermoplastic wheel rim
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Building & construction - A definite and technical success to help the fight against AIDS
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 16
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 17
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - China - The Chinese composite market: bright prospects
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 19
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - CFRP - Wind surpasses aerospace as top user of advanced compositematerials
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Sustainability - Acting on sustainability for business value
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 22
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 23
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Raw material - Resin and gelcoat compliant with the new railway standard
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 25
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 26
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Prepreg - Phenolic prepreg is welcome aboard Bombardier’s class 379 Electrostar EMU passenger trains
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Sandwich construction - Rolling stock: weight reduction pays off
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 29
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - CFRP - New carbon-fibre-reinforced composite for vehicle bodies and electric vehicles
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 31
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Design - Next generation composites – driving innovation in the ground transportation sector
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 33
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 34
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Structures - Hybrid structures for tailored structural automotive components
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 36
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 37
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Process - Composite reduces vehicle and sunroof weight and enables assembly and process innovations
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Joining - Investigating the properties and failure mechanisms of a damage-tolerant 3D-reinforced joint for lightweight structures
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 40
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 41
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 42
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 43
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 44
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Bonding - 3D sandwich panel manufacturing with great properties as result
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 46
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 47
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 48
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Corrosion - Glass fibre reinforcement type determines FRP corrosion performance
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 50
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 51
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Thermoplastics - The promise of fibrereinforced thermoplastics: low weight and recyclability
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 53
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Manufacturing - New mould manufacturing process
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 55
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Foam - A new product range for marine applications
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - Index
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - In the world
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 59
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 60
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