Page 8 - ILK Research Report 2020

The goal: series production of hybrid structures

Together with ten project partners under the coordination
of Brose Fahrzeugteile SE & Co. KG, Bamberg, scientists Holistic implementation of
from the Institute of Lightweight Engineering and Polymer hybrid construction methods
in series production
Technology at TU Dresden are developing a combined
physical and virtual process chain for fibre composite
plastic-metal hybrids in the project "hypro – Holistic Im- Supervised by:
plementation of Hybrid Structures in Series Production".
The aim is to make the production of hybrid components
industrially suitable for series production and at the same
time competitive.

Hybrid structures made of metal, thermoplastic-fibre
composite and plastic offer considerable lightweighting
potential, but have not yet been established on a large-se- In the project, the researchers and developers also want
ries scale. Existing uncertainties with regard to process to develop methods for the efficient design and layout of
capability and the effective process-structure-property hybrid structures based on the virtual mapping of the pro-
relationships are to be specifically eliminated in hypro. cess chain. In particular, their ability to be integrated into
The core of the process chain to be developed will be a assembly lines for series production will be investigated
flexible manufacturing cell based on injection molding using established joining technologies, and disassembly
combination technology, which will allow fully automated and repair concepts will be developed.
plasma-based pretreatment of a wide range of metallic
materials. The continuous inline acquisition of process data The scientists will demonstrate the practical readiness of
in the tailored plant, mold and handling technology will the developed process chain using a safety-relevant struc-
provide a comprehensive database for process analysis. tural component. In doing so, the team led by Prof. Maik
Proof of process capability and comprehensive data ac- Gude and Dr. Robert Kupfer intends to demonstrate the
quisition are carried out in a unit number range of 10,000. predictive capability of the process and structure simula-
tion and its suitability for industrial practice.
The hybrid structures are also to be digitized throughout
the development, characterization and production pro- The joint project hypro, funding code 03XP0284J, is funded
cesses. The merging of real and simulation data will then by the Federal Ministry of Education and Research on the
enable calculation-based non-destructive inline quality basis of a resolution of the German Bundestag under the
assurance and the prediction of component properties. supervision of the Project Management Agency Jülich PTJ.

Hybrid designs with generative metal structures and fibre
composites for high-performance electric motors

As part of the AdHyBau research project, SIEMENS AG, MT
Aerospace AG, the Fraunhofer Institute for Mechanics of
Materials (IWM), the Institute for Technical Physics (ITEP) at
the Karlsruhe Institute of Technology (KIT) and the Institute
of Lightweight Engineering and Polymer Technology at the
TU Dresden are developing new additive processes and
fibre composite-metal hybrid designs for use in cryogenic
environments. End-to-end design, simulation and mate-
rial qualification processes are being developed to put a
novel electric drive into operation as a virtual prototype.
fibre composite
AM metal
The main objective of the work to be carried out at the
ILK is to explore novel fibre composite-metal hybrid de-
signs. The combination of high-performance fibre com-
Generative manufacturing technologies enable optimized posite materials with additively manufactured metallic
cooling systems and a specific coil design to increase the elements enables structures that are significantly en-
power density of next-generation electric motors. hanced in terms of their functionality and performance.

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