Hybrid components made of metal and fibre-reinforced plastic (FRP) are becoming increasingly important, particularly in the context of lightweight automotive construction where new crash structures are required for electromobility. Hybrid components significantly reduce weight while maintaining high strength.
The single-stage forming and thermojoining process, which forms and joins both materials simultaneously, is of particular economic relevance. This approach significantly reduces tool and process costs, as a second forming tool, adhesives and complex pre-treatment are not required. Additionally, the use of fibre-reinforced thermoplastics significantly improves recyclability, enabling the component to be integrated into the circular economy and promoting sustainable lightweight construction.
Overall, the single-stage forming thermojoining process offers a scalable, economical and environmentally friendly alternative for the large-scale production of hybrid components, thereby strengthening the competitiveness of small and medium-sized enterprises (SMEs) in the future market of lightweight construction.
The aim of the project is the development of an one-step forming process for producing structural components made of steel and fibre-reinforced thermoplastics with high lightweight construction potential. To achieve this, a conductive surface pretreatment for galvanised steel sheets is being developed and tested. These sheets, together with fibre-reinforced thermoplastics (PA6), will then be used to test their suitability for joining. At the same time, the design of an isothermal forming tool is being developed alongside a simulation study of the tool's design. Finally, demonstrators will be produced by combined forming and tested for their specific bending strength and energy absorption.
Funding by: European Research Association for Sheet Metal Working e.V.
Funding period: 01.02.2023 – 31.01.2025, Extension without expenditure until 31.01.2026
Funding code: 01IF22651N
