Optimization of joining processes for new automotive metal-composite hybrid parts

Grant Agreement Nr: 609039 Collaborative Project - FP7-2013-NMP-ICT-FOF(RTD)

Final Event WP1 | REQUIREMENTS' ANALYSIS FOR JOINING COMPOSITE-METAL

Introduction to the project and summary of the work done

Author(s): Javier Romo Date: 24rthFebruary 2016

Target of the project

To optimize the joining process of composite – metal hybrid parts in order to apply the electromagnetic technology for automotive parts

2

Demonstrator identification, requirements and benchmarking

The development of this work package has allowed to define the

demonstrators for the three-end user involved in the consortium. The common characteristics of all of them is that the actual design is going to be

improved by the introduction of at least two parts, one of them made of composite and the other one made of metal to establish a hybrid joint.

The demonstrators selected have different geometries in order to cover the design of tubular hybrid joints and planar hybrid joints.

One of the criteria for the demonstrator selection was to be able to apply the knowledge generated to many other components.

The specifications for the three demonstrators have been collected. Also and analysis of the performance of the current demonstrator and a Life

Cycle Assessment have been done.

3

Demonstrator identification, requirements and benchmarking

Demonstrators selection: Shock absorber They high level requirements for the connexion are:

Structural part Has to be gas tight (high pressure) Minimum bending to withstand (good alignment) High pressures and temperature of work

Fatigue requirements and corrosion specifications have been collected

4

Demonstrator identification, requirements and benchmarking

Demonstrators selection: Brake pedal The requirements are:

To transmit the order of the driver to the braking system Not to damage the driver in a crash event

Thermal, mechanical and thermomechanical requirements has been analyzed

5

Demonstrator identification, requirements and benchmarking

Demonstrators selection: Bumper The requirements are:

To allow the vehicle to sustain o low energy impact. To mitigate injury to pedestrians.

Different crash test are going to be considered: ECE Regulation 42.

FMVSS_Part581: Bumper standard

RCAR: Low speed structural crash test protocol, issue 2.2, July 2011

RCAR: Bumper test, issue 2.0, September 2010

6

Selection and acquirement of materials for the applied research

Taken into account the demonstrators definition and the research to be done in

WP3 and WP4 several decisions on materials have been taken: Material selection: composite and metal. Material combination analysis. Material process.

7

Process

Material

Selection and acquirement of materials for the applied research

Material selection: Metal Materials considered:

Aluminum

Magnesium

High strength steel .

8

Selection and acquirement of materials for the applied research

Material selection: Matrix Selection criteria:

Corrosion resistance: galvanic corrosion Carbon fiber behaves as cathodic material

Steel, aluminium and magnesium behave as anodic

Cost

Damage resistance

Ductibility

Fire performance

Moisture influence

Processability

Strength

Thermal expansion

UV resistance

9

Selection and acquirement of materials for the applied research

Material selection: Reinforcement Selection criteria:

Strength and stiffness

Cost

10

Unidirectional Plain Twill Satin Basket Mock leno Prepreg Tapes and tows

Selection and acquirement of materials for the applied research

Process selection: Selection criteria:

Product form

Reinforcement layup

Processes considered: RTM

Resin infusion

Filament wilding

Pultrusion

Compression molding

Injection moulding

11

RTM Resin infusion Filament wilding Pultrusion Compression moulding Injection moulding

Technology specifications and assignment to demonstrators

EMJ Process description EMJ of tubular parts EMJ of flat parts General requirements and process specification Special requirements for EMJ of tubes Special requirements for EMJ of sheets

12

Technology specifications and assignment to demonstrators

EMJ process description It is a high velocity forming process using the energy density of a pulsed magnetic field. Applies pressure impulse on materials of good electrical conductivity The plastic strain of the material produce the crimping of the components

13

Technology specifications and assignment to demonstrators

EMJ of tubular parts It is principally possible by magnetic compression This configuration allows the use of fieldsharpers The joint obtained can be crimping or welding It is also possible by magnetic expansion

14

EMJ of flat parts The flat coils can be single turn coils or spirally wound multi-turn ones. Prediction of work piece behaviour is extremely difficult, without simulation nearly impossible. The joint obtained can be crimping, welding or riveting.

Optimization of joining processes for new automotive metal-composite hybrid parts

Grant Agreement Nr: 609039 Collaborative Project - FP7-2013-NMP-ICT-FOF(RTD)