In addition to thermoplastic-thermoplastic-composites design, the combination of fibre composites with classical construction materials such as steel can lead to a significant expansion of the range of applications due to using the material-specific advantages. With the novel 3D hybrid technology - a combination of high-strength steel, continuous fibre-reinforced thermoplastic and fibre-reinforced thermoplastic moulding compound - researchers have made a decisive step towards a high-volume production of hybrid lightweight structures. In addition to the technologically developed solutions, the bond strength between the various components and materials is a key issue in component and process development. In order to achieve the required joint strengths between the different materials, various process-adapted pre-treating methods have to be characterised. For this reason, the ILK carries out adapted tests of new material combinations with regard to the design of intrinsic hybrid structures in multi-material design.
For the comprehensive characterisation of the intrinsically joined hybrid structures, a novel hybrid test specimen was developed. On the one hand, these can be used to accurately reproduce the process conditions of the actual component manufacturing process, such as heating, transfer, forming, injection-moulding and cooling behaviour. On the other hand, the load cases occurring in the hybrid component can be better analysed with adapted specimen geometries. With the possibilities of shear tensile, peel pull, head pull and mix mode testing at a defined angle, the material combinations can be characterized in detail, providing extensive characteristic values for the numerical simulation of the bonding layer.
Using the novel hybrid test specimen, various pre-treating methods e.g. adhesion promoter systems, as well as surface structuring by means of laser processing, are investigated experimentally.