Page - (000013) - in Induktionsfügen von thermoplastischen Faserverbundwerkstoffen

Abstract Theuse of high-performance fiber-reinforcedplastics in automotive chassis shows ahighpotential for the emission reductionand the conservationof fossil fuels through lightweightdesign.Theavailability of amaterial specific joining technique sets the limit ofmaterial use case in the car body. In addition to the technical capacities of amethod to create a bond between two ormore parts in the car body, the technical opportunities, the capability check and the economic aspects have to be fulfilled. The study investigated the inductionwelding of carbon-fiber-reinforced thermoplastics.With the induced eddy currents in the carbonfibers the thermoplasticmatrixwasmeltedby thermal loss.Theproof of the process capabilitywas necessary for the industrial use of the inductionwelding in the body shop. One aspect at the study was the analysis of the process monitoring and the temperature controlled plasticizing as the first process step of the continuous welding. The second goal of the studywas to investigate and optimize the strength related re-consolidation of the locallymelted fusion zone. The major scope of the investigation, for the improvement of themechanical values of theweld seamwas laid on the active controlled cooling and the designated applied local pressure. For the optimization the consolidation process was split in active and passive parts. A semi-analytic method was used for a fast and economic weldability investigation and the weld parameter prediction. An industrial automatedweld systemwith a standardizedbody shop robot systemwasdesigned.The requirements for the designwere defined after an effect analysis of the inductionweld process. In the second part of the study the influence of theweld headpositionwas evaluated.The failure of the fusion zonewas investigatedbyx-raycomputer tomographyandscanningelectronmicroscopy.Todetermine the static mechanicalproperties theSingle-Lap-Shear-Testwasused.The inter laminar shear strengthvaluewas determined by the modified Compression-Shear-Test. Based on the investigations the guidelines for the parts and joint design were defined. The capability study and economic evaluation prove the possibility of the current industrial application at the body shop.