The central challenges in the development, production and application of hybrid structures are the interfaces between the individual materials. A new direct joining process in which the interconnection is obtained via intrinsic interfaces uses the Openair-Plasma® process working under atmospheric pressure. Here the metal surface is coated by plasma polymerization with a precursor that is matched to the metal and the thermoplastic to be directly molded on. Within the framework of the BMBF-funded joint research project “Integrated implementation of hybrid construction methods in series production – hypro” (funding code: 03XP0284C, duration 2.5 years) this process, which so far has only been verified on simple geometries, will be transferred to complex, three-dimensional components. Additionally, series-production capability of this new technology is to be demonstrated. The overall objective is the development of a versatile physical and virtual production chain for manufacturing hybrid components and proof of process capability.

In the subproject “Modelling of intrinsic hybrid connections and their virtual validation” inpro aims to develop the virtual process chain for such intrinsically joined hybrid components with high quasi-static loads, taking into account essential production-related changes in geometry and resulting internal stresses. With the expected project results, it should be possible to predict the load bearing behavior of intrinsically joined, fibre composite plastic-metal hybrid structures. Thus, variants of different materials and pretreatments can be analyzed using digital calculation methods in the future. The results will be used in turn as input parameters for structural simulations.

A total of ten partners are involved in the joint project, which started on May 1, 2020. Brose Fahrzeugteile SE & Co. KG, Bamberg is project coordinator.