Additive Prozesskette zur Herstellung von thermoplastischen Faserverbundbauteilen-Hybridbauteilen

  • Additive process chain for the production of thermoplastic fiber composite hybrid components

Janssen, Henning; Brecher, Christian (Thesis advisor); Fleischer, Jürgen (Thesis advisor)

1. Auflage. - Aachen : Apprimus (2020)
Book, Dissertation / PhD Thesis

In: Ergebnisse aus der Produktionstechnik 14/2020
Page(s)/Article-Nr.: 1 Online-Ressource (VIII, 164 Seiten) : Illustrationen, Diagramme

Dissertation, RWTH Aachen University, 2020


According to the current state of art, a strong demand exists for an economic and flexible production of tailor-made fibre composite components based on unidirectional thermoplastic semi-finished products. This thesis contributes to this topic with the research and development of an additive process chain for the production of thermoplastic fiber composite hybrid components. The main challenge in the production of FRP components is the processing of two different material phases. This yields to a strong influence of the single process steps on each other. In terms of value chain management, thermoplastic tapes offer a special opportunity to decouple the production of semi-finished products and materials from discrete component production and still have a sufficiently high degree of flexibility. Based on the physical models of the individual process steps impregnation, draping and heating, the process chain is optimized. This also includes a consideration of the process robustness, which is evaluated with a statistical model of the in-situ consolidation process, as well as the investigation of various possibilities for upscaling of the productivity and their effects on the overall equipment effectiveness. The gained knowledge leads to the development of a system technology for the production of load- and waste-optimized laminates. The resulting, highly integrated machine concept consists of an IR-based deposit system, which is optimized for the production of flat laminates by in-situ consolidation. It can be reproduced cost-effectively. This prototype machine system is used for process development and laminate production. On tape level it can be proven that the IR-assisted tape laying enables a robust consolidation process as well as a cut-minimized processing of unidirectional tapes. A detailed characterization of the laminates shows that the mechanical properties are comparable with laminates from conventional processes. A novel process combination is investigated for the processing of the manufactured laminates into thermoplastic hybrid components. This consists of a thermoforming process in which the laminate is joined with a thermoplastic functional structure in parallel to the main processing time. The additive rib structure also has the function of the forming stamp, so that only a single-sided, cost-effective metal die is required. By using a multi material reinforced composite structure, it is shown that a fusion-based connection of both joining partners can be achieved. A final evaluation of the hybrid components and the researched process chain answers the research question whether it is possible to manufacture load- and waste-optimized laminates from unidirectional tapes economically using in-situ consolidation. Furthermore, their processing into hybrid components is validated.