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WEB Mechanical joining of lightweight hybrid parts with cold formed pin structures

Tuesday (22.09.2020)
15:00 - 15:15 Z: Special Symposia II
Part of:

In an environment with increasing requirements on lightweight constructions, hybrid parts consisting of a high strength steel component and an aluminum alloy or a continuous fiber reinforced thermoplast (CFRT) offer great opportunities for high performance applications. The main advantage of this approach lies in the possibility to tailor the properties of the hybrid part to different demands of the application such as elevated temperatures and high requirements on weight related strength and stiffness, which could not be fulfilled with mono materials.

Despite the high potential of this approach, the joining operation poses a major challenge. Due to dissimilar physical properties, such as different thermal expansion coefficients and chemical incompatibilities established joining technologies without the use of auxiliary elements reach their limits. A method that proofed to be promising when joining dissimilar materials is the use of small diameter metallic pin structures which are inserted into the aluminum respectively CFRT component. Main challenges within this approach are the design and manufacturing of the pin structures as well as the process technology of the joining operation itself. When joining a steel part with a CFRT component via inserted pin structures, it is crucial, that the load bearing reinforcement fibers are displaced and rearranged in a way that does not significantly damage the fibers and consequently weakens the hybrid part. Therefore, it is necessary to understand the influence of the pin structure on the resulting fiber rearrangement to allow for an optimized pin design.

This presentation will give an overview of pin structure fabrication by extrusion from the sheet metal plane and the influence of pin geometry on the connection of a steel CFRT component.


Julian Popp
Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU)
Additional Authors:
  • David Römisch
    Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU)
  • Prof. Dr. Marion Merklein
    Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU)
  • Prof. Dr. Dietmar Drummer
    Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU)