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structures have the disadvantage of becoming thicker in the joint area, of fiber damage and stress increase at the bolts with the associated weight increase, and susceptibil- ity to corrosion. Typical applications lie in products for the aerospace


industry (lower rudder hinge, sandwich plates, rump seg- ment), in motor vehicle engineering (CFRP roof, railing arms), in wind turbine construction (rotor blade, rotor hub connection) and in general machine engineering (hydrau- lic elements, articulated arms for robots, power transmis- sion). In addition, a further motivation for the use of such hybrid materials could be the setting of a defined thermal expansion (for example, in heat pipes for satellites, tele- scopes or textile machinery). Te current research goals lie in the further develop- ment of the two concepts. For the foil concept, the studies are predominantly concentrated on the welding of alumi- num and titanium foils using lasers and the layer-by-layer production of the CFRP-titanium transition structure. For the fiber concept, research is being conducted into the integration of different fiber materials (glass, ceramic and basalt fibers) into aluminum die castings. Te studies focus on the process engineering production of the fiber/ aluminum part joint. In particular, research is being con- ducted into how the infiltration of metal melts into fiber materials and the positioning and fixing of the limp fibers during the casting process. Recent developments focus on the conception of a high pressure diecasting mold with modifications for partial sealing and fixing of the fibers. Te use of a specially designed mold for the infiltra- tion process aims to enable the process to be expanded to the industrial scale. Priority is being given here to the automatic fixing and partial infiltration of the fibers. Te further processing to create complete structures of alumi- num and CFRP is being carried out in collaboration with the project partners. At this stage, the fibers protruding from the cast structure are connected with carbon fiber and consolidated using thermoset matrix systems. 


压板粘合和螺栓进行连接。这样的结构的缺点是在连 接处变厚,螺栓处的纤维损坏和压力增大,以及重量 增加、易于腐蚀。


潜在应用


传统的应用领域包括航空航天工业(例如,下降的 方向舵铰链、夹层板、尾翼),汽车工程(例如碳纤 维复合材料车顶、扶手杆),风力发电设备(转子叶 片、转子中心连接件),以及通用设备工程(例如, 液压元件、机器人铰链臂、电力传输件)。此外,由 于复合材料具有稳定的热膨胀性能,它还将有进一步 的应用(例如卫星、望远镜或纺织设备的热导管)。


研究现状


目前的研究目标是使这两种方法有进一步的发展。 金属箔概念的研究,主要集中在使用激光焊接铝合金 和钛合金箔,以及碳纤维复合材料-钛合金过渡结构 的递层生产工艺。对于纤维材料的概念,弗劳恩霍夫 学院的科学家正在对不同纤维材料(玻璃、陶瓷和玄 武岩纤维)与铝合金压铸件集成进行研究。研究的重 点是纤维材料/铝合金连接部分的工艺过程。特别是, 还对金属熔液渗入纤维材料以及柔软的纤维材料在铸 造工艺中的定位和固定进行了研究。近期研究的重点 是,为纤维材料的局部密封和固定进行了修改压铸模 具的方案。在渗透工艺中使用特别设计的模具,其目 的是使该工艺的使用扩大到产业规模。首先要注意的 是纤维材料的自动固定和局部渗透。为了开发出完整 的铝合金-碳纤维复合材料结构,研究小组与项目合作 伙伴共同合作,开展了进一步的研究。目前,从铸件 结构中突出的纤维材料与碳纤维连接,通过热固性矩 阵系统加固。


Shown is a CFRP-aluminum hybrid joint.


碳纤维复合材料-铝合金的连接处


90 | FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION December 2015


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