FlexHyJoin: Vollautomatische Fertigungszelle zum effizienten Fügen von thermoplastischen FKV mit Metallen

FlexHyJoin: Fully automated production cell for efficient joining of thermoplastic FRPC with metals

The joining of fiber reinforced polymer composites with metals is becoming more and more popular due to the application potential in lightweight construction across all industries. In particular, thermoplastic fiber reinforced polymer composites (TP-FRPC) are of particular interest for mass production because they can be processed within short cycle times and welding can be used as an appropriate joining technique. FRPC components often have to be integrated into an existing metal structure, for which suitable joining techniques are essential.

In order to provide customized technologies for hybrid joining to OEMs, an international consortium of ten partners has developed a fully automated production cell for hybrid joining as a prototype for industrial mass production in the framework of the EU funded research project FlexHyJoin (www.flexhyjoin.eu). In the production cell the hybrid joining processes induction and laser joining are used to join components within short cycle times by a material and form closure between metal and matrix polymer of the FRPC, resulting in high bond strengths. In order to prepare the metal component for a positive fit, its surface is structured line-shaped perpendicular to the load direction by a high-speed laser. After joining, the joint is automatically controlled and evaluated by lock-in thermography for defects and air inclusions. Defects can be detected by the evaluation software developed for this application.

The presentation will not only show the production cell and the implemented technologies used, it will also present the achieved tensile shear strengths (DIN 1465), fatigue strength and resistance to corrosion in the climatic change test (BMW PR 308.2 and cataplasma test according to DIN EN 13523-27: 2009) of various inductively joined material combinations of laser-structured metal and continuously fiber-reinforced polyamide 6 (PA6), polypropylene (PP), polycarbonate (PC) and polyphenylene sulfide (PPS).