DE102014001132A1 - Process for the production of thermoplastic fiber-metal laminate components by means of forming processes and correspondingly produced fiber-metal laminate components - Google Patents

Abstract

The method according to the invention for the production of fiber-metal laminate components is based on a fiber-metal laminate semifinished product (1) comprising at least two sheet-like cover layers (2, 4) made of a metallic material with one between the metallic cover layers (2, 4) arranged layer (3) made of a fiber material (3). In this case, at least one monomer (16) is introduced before and / or during and / or after the deformation of the fiber-metal laminate semifinished product (1) in the region of the fiber layer (3) and there with the introduction of heat energy (8) the fiber material (3) envelopingly at least partially cured to a thermoplastic matrix during or after the fiber-metal laminate semifinished product (1) is formed into a fiber-metal laminate component. Furthermore, a correspondingly produced fiber-metal-laminate components will be described.

Description

The invention relates to a method for producing thermoplastic fiber-metal laminate components by means of forming methods according to the preamble of claim 1 and correspondingly produced fiber-metal-laminate components according to the preamble of claim 35.

In connection with the increasingly important lightweight construction of components used industrially and in large numbers, such as in the automotive industry, which were previously often made of purely metallic materials, the use of so-called fiber-reinforced composite materials is becoming increasingly important.

Fiber-reinforced composites (so-called composites) represent a relatively young group of materials that consist of the combination of a textile reinforcement structure (fibers) with a matrix material. As fiber materials mainly glass and / or carbon fibers are used for continuous fiber reinforced composites. It is then spoken of glass fiber reinforced plastics (GRP) or CFRP (carbon fiber reinforced plastics). The matrix materials used in industrial applications are almost exclusively polymeric materials, which are subdivided into the two main main groups thermosets and thermoplastics. The combination of thermosets and carbon fibers offers the best mechanical properties, but is also the most expensive. The use of glass fibers is much cheaper, but glass fibers have poorer mechanical properties. Fibers and matrix have different tasks within the composite component. While the fibers essentially absorb the tensile forces acting on the component, the matrix primarily serves to shape, maintain cohesion within the component, and absorb pressure and shear forces. While the mechanical properties are largely determined by the fiber, the physicochemical properties are highly dependent on the matrix material.

Particularly in the case of large and, above all, geometrically complex shaped components, different production methods are used for the production of such composites: the deposition of preimpregnated semi-finished products on molds with subsequent curing in an autoclave, so-called vacuum-assisted infusion method and so-called hand lamination method. In the manual lamination process, dry semifinished fiber products in the form of woven, laid or nonwoven fabrics are manually placed in a mold, subsequently impregnated with resin and manually consolidated. Curing can then be carried out under various environmental conditions, in addition to standard pressure and room temperature also often at elevated temperatures in heated molds. Typical applications are a variety of large components, such as for boat and tank construction. In vacuum-assisted infusion processes, dry textile semi-finished products are placed in a mold, covered with a venting fleece and then covered with foil and sealed from the environment. After applying a vacuum, inlets for the resinous matrix materials are opened, whereby the resin is pulled into the laminate by the vacuum. Due to the vacuum, a better compaction of the component can be achieved compared to the hand lamination method. Typical applications are z. As blades of wind turbines, structural and fairing parts of trucks and train cars. In the manufacture of semi-finished products impregnated by the tray, so-called prepregs are deposited in a mold, the resin liquefying by heating in an autoclave before the component hardens. Due to the pressure prevailing in the autoclave, an even better compaction of the component compared to the vacuum-based method can be achieved. Relevant applications are in particular structural components for aircraft construction, in racing vehicles such as in Formula 1 and high-quality skis.

Among the remaining production processes, the so-called resin transfer process (Resin Transfer Molding RTM) is of interest, but only permits the production of limited component geometries, in particular with regard to the component size and the maximum achievable complexity of the components. The RTM method is based on the use of two-part molds. Usually, a dry preform (preform) is first produced and then inserted into a mold. After closing the mold in a press, resin is injected into the cavity between the mold halves. After closing the resin inlets, the cure begins, often at elevated temperature, by heating the mold. Typical applications of this process are automotive, rail and aircraft components.

Although the above-described production of pure fiber-reinforced components more and more z. B. is also used for the production of essential strength-relevant parts of vehicle bodies, such manufactured components have system-related disadvantages compared to the usual components made of metallic materials. It has therefore already become known to combine the advantages of the metallic materials with the advantageous properties of fiber-reinforced materials in so-called fiber-metal laminates (FML) of layered arrangements of metallic layers and fiber-reinforced plastic layers.

Fiber-to-metal laminates (FML) can combine the respective properties of metallic and polymeric materials and, compared to monolithic sheet materials or pure fiber-reinforced plastics, have a high specific strength and improved fatigue properties, depending on the application and field of application. In addition, by a suitable combination of metals and plastics, an increase in the bending stiffness can be achieved without significantly increasing the weight of the component. In the automotive industry, plastic-metal laminates are used as structural elements and decorative components. Composite sheets for structures consist of thin cover sheets of aluminum or steel (thickness 0.2-0.25 mm) and an intermediate layer of polypropylene (PP, thickness 0.4-0.8 mm). Furthermore, such fiber-metal laminates have good sound insulation properties.

So far, however, the range of applications of such fiber-metal laminates z. B. limited due to existing challenges in the transformation of the sheet-like starting materials. Although these fiber-metal laminates are characterized by a good resistance to fatigue failure and low crack propagation speeds, but are disadvantageous u. a. the limited deformability of the produced materials due to the duromer matrix to complex geometries which are frequently required for the components. Although fiber-metal laminates are therefore fundamentally powerful hybrid material concepts that are already being used commercially as structural materials, above all in the aerospace industry. A broader technical use fails due to lack of suitable production technologies to produce fiber-metal laminates in reproducible quality in large-scale manufacturing processes with near-net shape geometries that go beyond slightly curved, flat components. For this purpose, either multi-stage manufacturing processes are necessary today or the production takes place only to a limited extent fiber-composite, by folding or breaking the fibers are accepted in highly deformed areas.

In addition to the pure bending of more contoured components, it has hitherto not been economically possible to produce component geometries otherwise produced by deep-drawing also by means of fiber-metal laminates. Deep drawing is the most commonly used in industrial practice forming process for the production of sheet metal parts with high volumes and low cycle times. The normal compressive stresses that are generated by the hold-down, have the task of preventing irreversible wrinkling in the flange due to the tangential compressive stresses. The forming limits arise when deep-drawing purely metallic sheets by the occurrence of snags or by the formation of wrinkles. Both types of failure limit the permissible work area. However, in addition to the known failure modes of conventional thermoforming processes in plastic-metal laminates, additional effects such as slipping and delamination of the layers occur. Tangential compressive stresses directly lead to wrinkling during tissue reshaping due to the low bending stiffness of the tissue.

To produce even more contoured moldings made of fiber-metal laminates, there are various approaches that differ in particular by the semi-finished products used. Thus, on the one hand, it is possible to use fiber-metal laminates as sheet-like flat semi-finished products and to reshape them analogously to monolithic sheet materials. In other approaches, the sheet metal materials are first conventionally reshaped and then the fiber-reinforced materials inserted or molded sheet metal parts (so-called sequential approach). Also, the sheets may first be conventionally reshaped and then the prepreg material may be pressed into the formed sheet in a press process. Due to the temperature of the tool it cures simultaneously, with residence times in the press are necessary.

In the so-called polymer injection molding, the sheet metal material is reshaped by means of the pressure of the plastic melt and, at the same time, the plastic material and form-fittingly connected to the metal sheet. Also described are methods in which a textile insert, for. B. glass fibers, between two metallic cover sheets is glued. After curing of the adhesive only a small formability of these multi-layer sheets was found in thermoforming experiments.

Components made of metal-plastic composites with certain plastic materials, for example for the aerospace industry, can be produced directly in the autoclave in the final form by means of a self-forming technique. Here, the individual layers are stacked in the autoclave and formed by the vacuum pressure in the autoclave to the appropriate geometry. Deep drawing of these semi-finished products is not possible, so their deformation is limited to bending. However, the geometry of the manufacturable components is limited to single and doppelachgekrümmte components, as i. d. R. only stretch-drawing can be used. It also had to be stated that metal-plastic composites with an intermediate layer of glass fiber have a significantly lower forming capacity than composites without glass fiber content.

The transformation of three-dimensional, in particular deep-drawn components is according to the current state of the art only in sequential Procedure is possible. When bonding already formed component as described, the production requires two separate forming steps and an additional step for joining these components, which is associated with long process times and high costs.

Object of the present invention is therefore to provide an improved process for the production of fiber-metal-laminate components, in which also more strongly contoured components can be manufactured safely and economically and to provide corresponding fiber-metal-laminate components.

The solution of the object of the invention results in terms of the method of the characterizing features of claim 1 and with respect to the fiber-metal laminate components of the characterizing features of claim 35 in cooperation with the features of the associated preamble. Further advantageous embodiments of the invention will become apparent from the dependent claims.

The invention in terms of the method is based on a process for producing fiber-metal laminate components, starting from a fiber-metal laminate semifinished product of at least two sheet-like cover layers of a metallic material with a layer arranged between the metallic cover layers fiber material. Such a generic method is further developed in an inventive manner that at least one monomer before and / or during and / or after the deformation of the fiber-metal laminate semifinished product introduced into the region of the fiber layer and cured there at least partially to a thermoplastic matrix is, during and / or after the fiber-metal laminate semi-finished product is formed into a fiber-metal laminate component.

This method offers the great advantage that the injection of the at least one monomer into the fiber layer takes place before or during or at least partially even after the forming process and thus the curing of the monomer can begin during the forming process. In addition, the inventive method has the advantage that the at least one monomer of the thermoplastic matrix so that at least partially polymerized during or after the forming and thus has the ability to chemically connect with the then at least partially or even completely transformed layers of the metallic Produce materials, which significantly improves the adhesion between the metallic layers and the fiber composite layer. This is due to the fact that the matrix forming from the reactive monomer has not yet completely polymerized during the transformation. Therefore, the boundary layer to the layers of the metallic materials forms substantially only after the forming, so that a delamination between metal and plastic during the forming is not expected and a rearrangement of the fibers due to the finished part geometry is made possible during the forming. As a preferred polymeric manufacturing method here preferably the T-RTM technology (Thermoplastic Resin Transfer Molding, a variant of the SRIM technology for sheet-like components) are used.

Thermoplastic matrix fiber-metal laminate components have fundamental advantages in terms of forming technology compared to those with thermoset matrix. However, interfacial optimization is difficult for a matrix already in the process as a polymer. Therefore, the use of an in-situ polymerizing, reactive thermoplastic matrix offers the best solution in terms of interface optimization and formability and at the same time serves as a sliding medium during the forming process. Such reactive thermoplastic matrices have a process window of a few minutes, which are both manufacturing technology (process window for the transformation) as well as economically interesting (cycle times for the entire production of the fiber-metal-laminate component). They represent the best possible solution for not significantly increasing the cycle times in comparison to conventional sheet metal forming and significantly reducing them in comparison to the conventional RTM or the autoclave process (process window in the range of approx. 30 minutes or more). In general, here under forming any method of umomtechnischen processing of materials should be included, even if in the further method of the invention is essentially explained by the examples deep drawing and extrusion.

Structural components of fiber-metal laminates can intrinsically, d. H. hybridized in an optimized, direct manufacturing process, wherein this hybridization based on the use of a reactive, monomeric precursor of a thermoplastic matrix (T-RTM) in combination with metallic sheet materials (eg aluminum alloys or steel materials and magnesium alloys). The idea is that the low viscosity of the monomer in the fiber layer during the deformation still allows fiber rearrangements and so large transformations of the fiber-metal laminate can be done intrinsically directly in the consolidation phase, without damaging the fiber composite component. The resulting thermoplastic matrix offers significant advantages over conventional solutions in duromer matrix.

The advantages of in situ hybridization are, in particular, a high degree of integration of the process into the usual production chain of forming processing, a short cycle time for the production of the composite, a fiber-suitable formability in the forming process as well as subsequent formability, repairability and good separability with regard to a Recycling by the thermoplastic bonding of the metal layers and the fiber reinforced layer.

It is of particular advantage in this case if the introduction of the at least one monomer and / or the wrapping of the fiber material and / or the at least partial curing of the at least one monomer takes place with the introduction of thermal energy. By introducing thermal energy, the infiltration of the monomer into the fiber layer and the required time period as well as the beginning of the polymerization can also be influenced to a large extent via the temperature and the temperature control. In this case, in a further embodiment, the introduced thermal energy allow a curing of the at least one monomer at temperatures in the range of at least 130 ° C, preferably of 200 ° C.

It is also conceivable that the thermal energy is introduced by a temperature of the forming tool in the fiber-metal laminate semifinished product. So z. B. used in the forming or before forming heat to be used to promote the polymerization, it is also conceivable that the forming tool is heated or tempered specifically to run the polymerization in the desired manner and without inadmissible temperatures.

Of particular advantage in particular for the handling of the fiber layer in the production of the fiber-metal laminate semifinished product is that the fiber layer can be introduced dry between the two adjacent layers of the metallic material. As a result, an at least semi-automatic production of the fiber-metal laminate semifinished product is much easier, and naturally no unwanted polymerization processes can take place in the prepared fiber-metal laminate semifinished product, since the monomer is not yet introduced into the layer at this time ,

For the homogeneity and the degree of filling of the fiber layer with the monomer, it is of particular advantage if the at least one monomer is injected under pressure into the region of the fiber layer. This allows this typically low viscosity monomer to completely penetrate the entire fiber layer and fill it to saturation. The prerequisite for this is that the edges of the fiber-metal laminate semifinished product are sealed positively and / or non-positively against leakage of the introduced monomer, so that the pressed-in monomer does not escape from the fiber layer in a manner contrary to regulations and can fill the entire fiber layer under pressure. For this purpose, it is conceivable in a first embodiment that the edges of the fiber-metal laminate semifinished product are themselves connected to each other for sealing, for. Another embodiment could be that the edges of the fiber-metal laminate semifinished product are sealed by the force of parts of the forming tool, as in the case of deep drawing by corresponding shaping of the blank holder or during extrusion by leading rollers or the like. May be generated. In the case of a sealing of the fiber-metal laminate semifinished product, as described above, z. B. in a forming tool, the fiber layer can be inserted between the sheets and this infiltrated in three different processes. The processes differ by the time of infiltration. It can be infiltrated before, after or during the transformation. Here, the development of a suitable sealing concept for the low-viscosity monomer, which is injected between the sheets, plays a crucial role. In addition, a clamping concept for a targeted fiber fixation of the fiber layer between the metallic sheets in the mold may be of importance.

It is of particular advantage that the layer of the fiber material can be formed from woven fabrics and / or loops and / or nonwovens of fibrous materials, in particular of glass fibers or carbon fibers, so that different depending on the desired properties of the fiber-metal laminate component Fibers, different fiber crosslinks and different fiber lengths and fiber orientations, possibly mixed with each other can be selected. This allows a substantial influence on the properties of the polymerized fiber composite layer and thus also of the fiber-metal laminate semifinished product or of the fiber-metal-laminate component produced therefrom overall.

In a further embodiment, it is conceivable that the surfaces of the sheet-like layers, which come into contact with the layer of the fiber material, are chemically and / or physically and / or mechanically cleaned of impurities or surface deposits before forming. As a result, an improvement in the adhesion of the at least one polymerizing monomer can be achieved, which prevents delamination during the forming, but above all also on the finished fiber-metal-laminate component become. Here, after cleaning the surfaces of the sheet-like layers also z. B. a new oxide layer of higher quality and / or improved adhesion for the subsequently applied monomer can be applied. Alternatively, after cleaning the surfaces of the sheet-like layers, a protective layer, in particular a dense and flexible mineral glass layer can be applied, which serves as additional corrosion protection of the sheet-like layers and z. B. prevents interim corrosion of cleaned, but not further processed sheets. For this purpose, for example, on a layer of aluminum under the mineral glass layer, a gradient layer are applied, which is initially soft and flexible (SiOxCyHz) and then continuously harder, but less flexible (in the direction of pure SiO2).

In principle, it is conceivable that for the sheet-like layers of metallic material of any kind, but especially steel materials and / or light metal materials and / or difficult to convert materials, preferably magnesium materials is used. In this case, the same metallic material can be used for both metallic layers of a fiber-metal laminate semifinished product, but it is also conceivable to use different metallic materials or at least partially different metallic materials for each layer. Also, the thickness of the layers of the metallic materials uniform or nonuniform, possibly even sections are designed to be non-uniform, approximately at exactly where in the later fiber-metal laminate component special loads occur, a reinforcement of the layers of the metallic materials provided. By way of example only, aluminum alloys of the 5XXX and 6XXX series or even steels DC06 and / or DP 600 can be used as the metallic material for the sheet-like layers.

Furthermore, it is conceivable that more than two sheet-like layers are each layered with the interposition of a layer of a fiber material to form a fiber-metal laminate semifinished product. In this way, a further influencing of the properties of the fiber-metal-laminate component can be achieved, wherein in each case different metallic layers or fiber layers or used monomers are conceivable in the individual layers of such a formed fiber-metal laminate semifinished product.

As a particularly preferred forming method, the inventive method for a deep-drawing process with hold-down and thermoforming dies can be used.

In another embodiment, the inventive method for extrusion can be used as a forming process in which the metallic layers are formed by an extrusion molding process.

In an advantageous embodiment, it is conceivable that the sheet-like layers are formed from a metallic material during extrusion from two mutually arranged at an angle sections of the same extruded profile or two sections of two juxtaposed extrusion profiles. In this case, the layers of the fiber-metal laminate semifinished product are produced by extrusion only immediately before the connection with the fiber layer and thus the production of the fiber-metal laminate semifinished product, whereby the process heat of the extrusion process is used to accelerate the temperature control of the polymerization process of the monomer can be. Also, this process can proceed continuously, both in terms of the formation of the metallic layers, as well as in terms of the insertion of the fibrous layer and the incorporation of the monomer. As a result, this method of production is particularly economical. Also, by using two sections of two different extruded profiles lying adjacent to each other, different metallic materials can be used for the metallic layers and combined with each other.

In a further embodiment, the layer of fiber material between the mutually assignable sections of the extruded profile or the two sections of successive extrusion profiles can be introduced before the mutually attributable sections of the extruded or come to rest, such as by between the sections of Metallic materials, the fiber layer z. B. withdrawn from a roll and passed between the sections of the metallic materials. In this case, in a further embodiment, the at least one monomer is applied to the layer of the fiber material, preferably without pressure and sprayed to saturation of the layer before the mutually attributable sections of the extruded or come to rest each other. In this case, a pressurized introduction of the monomer is more complex, since this would have to be ensured in the continuous process, a secure seal of the continuously produced strand. In a further refinement, after the introduction of the at least one monomer and the layer of the fiber material, the sections of the extruded profile can then preferably be pressed against each other by rolling, and thus joined together during the incipient polymerization. But it is also a different connection method than rolling conceivable.

In another embodiment, as a forming process, a roll forming can be used, in which the fiber-metal-laminate semi-finished product is formed by roll forming. Here, the fiber-metal-laminate semi-finished product can be prepared in a continuous or piecewise configuration as in deep drawing as described above and formed by a roll forming with simultaneous incipient polymerization of the monomer in the final form of the fiber-metal laminate component.

With regard to the materials to be used for forming the thermoplastic matrix of the fiber composite layer, preference may be given to using different reactive monomers or comparable substances, some of which are given below by way of example only. It is important here that the polymerization, unlike the usually thermosetting resins that are otherwise usually used for the production of fiber composite layers, runs much faster and therefore shorter cycle times in the range of a few minutes in the tool can be achieved until the molding.

With particular preference, a reactive, monomeric precursor of a thermoplastic matrix (T-RTM) with a starting viscosity of low viscosity can be used to form a thermoplastic matrix in the layer of the fiber material. Examples which may be considered of some and not exhaustive are the thermoplastic curing monomer caprolactam which polymerizes to cast nylon 6 (PA6G). Such a basically known caprolactam monomer polymerized with the addition of an initiator or catalyst and an activator to an anionically polymerized polyamide 6, wherein the reaction temperature of the caprolactam monomer between 130 and 160 ° C is desirable. With such process control, the complete polymerization of the caprolactam monomer can already take place within 3 minutes, whereby in the method according to the invention short and economically interesting cycle times for the production of fiber-metal-laminate components can be achieved.

Due to various procedural advantages, the processing of caprolactam to PA6G matrix is preferred in practice. The very low water-like viscosity of about 5 mPa · s makes it possible to use conventional duromer processing methods such as resin transfer molding (RTM). The influence of the activator and catalyst ratio, as well as the polymerization temperature and time on the average molecular weight and the degree of crystallinity allows a substantial influence on the polymerization process. The polymerization time can be adjusted by the choice of activator and catalyst combinations, and their ratio in a wide range.

For the chemical implementation of the G-PA 6 polymerization, which is also intended to realize the connection to the metal layers, suitable metals for the suitability of polymerization of caprolactam and sheet metal forming must be selected and prepared. At the same time, to achieve high-quality polymerization, it is necessary to achieve chemical compatibility between the reactive monomer and the fiber material. Decisive in the choice of fibers is a suitable for anionic polymerization sizing, a semi-finished fiber, which can be well drape in the later manufacturing process and a corresponding predrying of the fiber material in order not to hinder the reaction.

Alternatively, as the thermosetting monomer, lauryllactam may be used which polymerizes to PA12 or cyclobutylene terephthalate which polymerizes to polybutylene terephthalate.

The invention with regard to the fiber-metal laminate component describes a fiber-metal laminate component comprising a fiber-metal laminate semifinished product of at least two sheet-like cover layers of a metallic material with a layer of a fiber material arranged between the metallic cover layers , in particular produced according to the method according to claim 1. In such a generic fiber-metal laminate component, at least one monomer is present in the region of the layer of the fiber material before and / or during and / or after the deformation of the fiber-metal laminate. Semi-product can be introduced, wherein the at least one monomer during and / or after the deformation of the fiber-metal laminate semi-finished to the fiber-metal laminate component is at least partially cured to a thermoplastic matrix.

The essential properties and advantages of fiber-metal laminate components constructed and manufactured in this way have already been explained in detail in relation to the method according to the invention. It is therefore only referred to component specific features extra, otherwise reference is made to the description of the process in its entirety for the explanation of the fiber-metal laminate components according to the invention itself.

The polymerized layer of the fiber composite matrix can be the thermoplastic hardening Monomer caprolactam, which polymerizes to cast nylon 6 (PA6G). Alternatively, it is also possible to use laurolactam which polymerizes to PA 12, or cyclobutylene terephthalate which polymerizes to polybutylene terephthalate.

As metal material for the sheet-like layers, aluminum alloys of the 5XXX and 6XXX series or steels DC06 and / or DP 600 can be used. In addition, the difficult to transform magnesium alloys for the sheet-like layers are conceivable. All the above materials are given by way of example only and a variety of other metallic materials may also be included in the invention.

It is also conceivable that more than two sheet-like layers are each layered with the interposition of a layer of a fiber material to a fiber-metal laminate semifinished product.

The layer thicknesses of the metallic materials and the fiber-reinforced composite material can be specified depending on the application, z. B. to increase the sound attenuation, a thicker fiber layer can be provided.

It is also conceivable that, at least in sections, more than one layer of a fiber material is stacked between the metallic layers in order to produce locally different properties of the layer of the fiber material. Accordingly, the thickness of the metallic layers can be varied as a whole or locally.

A particularly preferred embodiment of the method according to the invention is shown in the drawing.

Show it:

1a - 1d - The sequence of a method according to the invention of the in-situ production of fiber-metal laminate components of layered constructed fiber-metal laminate semifinished products of metallic cover sheets and fiber composite core and a polymerization of at least one monomer in the forming of the fiber-metal laminate Halves using the example of a deep drawing process in a schematic flow chart,

2a - 2 B - An inventive method and a correspondingly produced fiber-metal-laminate component using the example of an extrusion process.

In the 1 is the typical sequence of a method according to the invention of the in-situ production of fiber-metal laminate components from layered constructed fiber-metal laminate semifinished products of metallic cover sheets and fiber composite core and a polymerization of at least one monomer in the forming of the fiber-metal Laminated semi-finished by the example of a thermoforming process shown in a schematic flow chart.

In the first step according to 1a should the platinum-like metallic materials 2 . 4 be pretreated for better adhesion or adhesion. This can be done both chemically and mechanically as well as physically. In the 1a is a plasma treatment with a plasma jet 11 from a plasma torch 10 to recognize the at least one side of the metallic material 2 . 4 treated over the entire surface and thereby increases the adhesion to this surface. Also, in this pretreatment step z. As protective layers, adhesion promoter layers or the like. Are applied.

In the next step according to 1b become the fiber-metal laminate semi-finished products 1 Layered fiber fabrics 3 or also fibrous webs or fibrous webs which are still dry in this step and the metallic layers 2 . 4 produced by stacked arrangement on top of each other. This can be done manually or semi-automatically, as the dry fiber layer is easy to handle.

In a third step according to 1c becomes this fiber-metal-laminate semi-finished product 1 placed in a deep drawing press, not shown, with a thermoforming tool, of which only the thermoforming die 6 as well as the hold-down 7 are shown. The deep-drawing die, not shown, is in a known manner above the thermoforming die 6 arranged and moves during the deep drawing process vertically in the thermoforming die 6 into it. By the power of the hold-down 7 becomes the fiber-metal-laminate semi-finished product 1 in the edge area on the top of the thermoforming die 6 pressed it by circulating drawing beads 9 for annular sealing of the interior of the fiber-metal laminate semifinished product 1 comes. Thus, now the injection of the monomer 16 via one with the interior of the fiber-metal laminate semifinished product 1 related injection channel 5 done and start the thermoforming process. In this case, the interior of the fiber-metal laminate semifinished product 1 with the fiber material 3 completely with the monomer 16 filled and the polymerization process of the reactive monomer 16 can start.

In a next step according to 1d the forming takes place (it is in 1d a degree of transformation that has not yet been completed) with the onset of curing of the monomer 16 by polymerization during the ongoing forming of the fiber-metal laminate semifinished product 1 to a simplified illustrated cup. It is also conceivable that the deformation at elevated temperature (temperature of the tool 6 on z. B. 200 ° C) is performed so that the curing process starts during the forming, which leads to an additional influence on the material flow and can further reduce the process times. The temperature of the tool 6 This can be exemplified by heatable heating cartridges 8th take place with the beginning of the forming and also afterwards. A tempering of the tool 6 Not only can cure the monomer in the fiber layer 3 be used to the thermoplastic matrix, but also for the transformation of difficult to convert material such. As magnesium alloys or the like. Serve.

In a final step according to 1e Now, after completion of the transformation, the complete polymerization of the monomer takes place 16 by polymerization in the fiber layer 3 , whereby the matrix of the fiber composite layer is formed. Here is the fiber-metal laminate semi-finished product 1 completely transformed and it is after completion of the polymerization, the finished fiber-metal-laminate component before. This final polymerization takes place for. B. by tempering using the already mentioned heating cartridges 8th ,

In the 2 another embodiment of the method according to the invention and a correspondingly produced fiber-metal laminate component is shown schematically using the example of an extrusion process and will be described briefly below.

During extrusion one becomes on a roll 20 wound fiber fabric 3 or fiber cladding between two at high temperature (about 250 ° C) and possibly by fans 14 cooled from two superposed extruders 12 . 13 emerging rectangular profiles 15 mechanically inserted and previously in a spray station 17 both sides with monomer 16 sprayed until completely soaked. In a subsequent step, the strands of rectangular profiles that come to lie on top of each other become superimposed 15 and with monomer 16 sprayed fiber fabric 3 by means of rollers 18 rolled together and thus permanently connected. It is conceivable, by another staggered roller 19 To bring the united strand by rolling in a certain curvature shape.

A correspondingly produced by extrusion component of metallic layers 2 ' . 4 ' and a fiber composite layer disposed therebetween 3 ' is in the 2 B schematically illustrated for the simplest case of a planar component.

LIST OF REFERENCE NUMBERS

1

Fiber-metal laminate semifinished

2

metallic layer

3

fiber layer

4

metallic layer

5

Injection channel

6

Tiefziehgesenk

7

Stripper plate

8th

Cartridge Heater

9

Down device Beading

10

plasma torch

11

plasma jet

12

extruder

13

extruder

14

fan

15

emerging strand of metallic material

16

Monomervorrat

17

spray nozzles

18

roller

19

bending roller

20

Roll of fiber layer

Claims (44)

Process for the production of fiber-metal laminate components starting from a fiber-metal-laminate semi-finished product ( 1 ) of at least two sheet-like cover layers ( 2 . 4 ) of a metallic material with one between the metallic cover layers ( 2 . 4 ) layer ( 3 ) of a fiber material ( 3 ), characterized in that at least one monomer ( 16 ) before and / or during and / or after the forming of the fiber-metal laminate semifinished product ( 1 ) in the area of the fiber layer ( 3 ) is introduced there and at least partially cured to form a thermoplastic matrix, during and / or after the fiber-metal laminate semifinished product ( 1 ) is converted to a fiber-metal laminate component. Process according to claim 1, characterized in that the at least one monomer ( 16 ) is polymerized to a thermoplastic material. Method according to one of claims 1 or 2, characterized in that the introduction of the at least one monomer ( 16 ) and / or the wrapping of the fiber material ( 3 ) and / or the at least partial curing of the at least one monomer ( 16 ) with the introduction of thermal energy ( 8th ) he follows. A method according to claim 3, characterized in that the introduced heat energy ( 8th ) a curing of the at least one monomer ( 16 ) at temperatures in the range of at least 130 ° C, preferably 200 ° C allows. Method according to one of claims 3 or 4, characterized in that the thermal energy ( 8th ) by a temperature of the forming tool ( 6 . 7 ) into the fiber-metal laminate semifinished product ( 1 ) is introduced. Method according to one of the preceding claims, characterized in that the fiber layer ( 3 ) dry between the two adjacent layers ( 2 . 4 ) is introduced from the metallic material. Method according to one of the preceding claims, characterized in that the at least one monomer ( 16 ) under pressure in the area of the fiber layer ( 3 ) is injected. Method according to one of the preceding claims, characterized in that the boundaries of the fiber-metal laminate semifinished product ( 1 ) with respect to an exit of the introduced monomer ( 16 ) positive and / or non-positive ( 9 ) are sealed. A method according to claim 8, characterized in that the boundaries of the fiber-metal laminate semifinished product ( 1 ) are connected to each other for sealing. A method according to claim 8, characterized in that the boundaries of the fiber-metal laminate semifinished product ( 1 ) by the force of parts ( 7 . 9 ) of the forming tool ( 6 ) are sealed. Method according to one of the preceding claims, characterized in that the fiber layer ( 3 ) are formed from woven fabrics and / or loops and / or nonwovens of fibrous materials, in particular of glass fibers or carbon fibers. Method according to one of the preceding claims, characterized in that the surfaces of the sheet-like layers ( 2 . 4 ), which with the fiber layer ( 3 ), are chemically and / or physically and / or mechanically cleaned of impurities or surface deposits prior to forming. A method according to claim 12, characterized in that after cleaning the surfaces of the sheet-like layers ( 2 . 4 ) a new oxide layer of higher quality and / or improved adhesion for the subsequently applied monomer ( 16 ) is applied. A method according to claim 12, characterized in that after cleaning the surfaces of the sheet-like layers ( 2 . 4 ) a protective layer, in particular a dense and flexible mineral glass layer is applied, which serves as additional corrosion protection of the sheet-like layers ( 2 . 4 ) serves. A method according to claim 14, characterized in that below the mineral glass layer, a gradient layer is applied, which is initially soft and flexible (SiOxCyHz) and then continuously harder but less flexible (in the direction of pure SiO 2). Method according to one of the preceding claims, characterized in that as the metallic material for the sheet-like layers ( 2 . 4 ) Steel materials and / or light metal materials and / or difficult to convert materials, preferably magnesium materials are used. A method according to claim 16, characterized in that as metallic material for the sheet-like layers ( 2 . 4 ) Aluminum alloys of the 5XXX and 6XXX series can be used. A method according to claim 16, characterized in that as metallic material for the sheet-like layers ( 2 . 4 ) Steels DC06 and / or DP 600 can be used. Method according to one of the preceding claims, characterized in that more than two sheet-like layers ( 2 . 4 ) in each case with the interposition of a layer of a fiber material ( 3 ) to a fiber-metal laminate semifinished product ( 1 ) are layered. Method according to one of the preceding claims, characterized in that the forming method used is a deep-drawing method with hold-down device ( 7 ) and thermoforming stamp is used. Method according to one of the preceding claims, characterized in that extruding ( 12 . 13 ) is used. A method according to claim 21, characterized in that the sheet-like layers ( 2 . 4 ) of a metallic material during extrusion ( 12 . 13 ) of two at an angle arranged portions of the same extruded profile ( 15 ) or from two sections of two adjacent extruded profiles ( 15 . 15 ' ) is formed. Method according to one of claims 21 or 22, characterized in that the fiber layer ( 3 ) between the mutually assignable sections of the extruded profile ( 15 ) or the two sections of each other upcoming extruded profiles ( 15 . 15 ' ) is introduced before the mutually assignable sections of the extruded or extruded ( 15 . 15 ' ) come to rest on each other. Process according to claim 23, characterized in that the at least one monomer ( 16 ) on the fiber layer ( 3 ), preferably without pressure and until saturation of the layer, sprayed on ( 17 ) before the juxtaposed sections of the extruded profile (s) ( 15 . 15 ' ) come to rest on each other Method according to one of claims 21 to 24, characterized in that after the introduction of the at least one monomer ( 16 ) and the fiber layer ( 3 ) the sections of the extrusion profile (s) ( 15 . 15 ' ) preferably by rolling ( 18 ) are pressed against each other. Method according to one of claims 21 to 25, characterized in that as thermal energy ( 8th ) for the at least partial curing of the at least one monomer ( 16 ) the heat energy of the extruded or extruded profiles ( 15 . 15 ' ) after the immediately preceding extrusion ( 12 . 13 ) is being used. Method according to one of the preceding claims, characterized in that as a forming process, a roll forming is used, in which the fiber-metal-laminate semi-finished product ( 1 ) is formed by roll forming. Method according to one of the preceding claims, characterized in that to form a thermoplastic matrix in the fiber layer ( 3 ) a reactive, monomeric precursor of a thermoplastic matrix (T-RTM) is used in the initial state of low viscosity. Method according to one of the preceding claims, characterized in that caprolactam is used as thermoplastic curing monomer, which polymerizes to cast nylon 6 (PA6G). A method according to claim 29, characterized in that the caprolactam monomer polymerized with the addition of an initiator or catalyst and an activator to an anionically polymerized polyamide 6. A method according to any one of claims 29 or 30, characterized in that the reaction temperature of the caprolactam monomer is between 130 and 160 ° C. A method according to any one of claims 29 to 31, characterized in that the complete polymerization of the caprolactam monomer takes place within 3 minutes. Process according to one of the preceding claims, characterized in that the thermoplastically curing monomer used is laurolactam which polymerises to form PA12. Process according to any one of the preceding claims, characterized in that the thermoplastic curing monomer used is cyclo-butylene terephthalate which polymerizes to polybutylene terephthalate, Fiber-metal laminate component comprising a fiber-metal laminate semifinished product ( 1 ) of at least two sheet-like cover layers ( 2 . 4 ) of a metallic material with one between the metallic cover layers ( 2 . 4 ) layer ( 3 ) made of a fiber material, in particular produced according to the method according to claim 1, characterized in that in the region of the layer ( 3 ) of the fiber material at least one monomer ( 16 ) before and / or during and / or after the forming of the fiber-metal laminate semifinished product ( 1 ), wherein the at least one monomer ( 16 ) during and / or after the forming of the fiber-metal-laminate semi-finished product ( 1 ) to the fiber-metal laminate component at least partially cured to a thermoplastic matrix. Fiber-metal laminate component according to claim 35, characterized in that the thermoplastic-curing monomer ( 16 ) Has caprolactam which polymerizes to cast nylon 6 (PA6G). Fiber-metal laminate component according to claim 35, characterized in that the thermoplastic-curing monomer ( 16 ) Has lauryl lactam which polymerizes to PA12. Fiber-metal laminate component according to claim 35, characterized in that the thermoplastic-curing monomer ( 16 ) Cyclo-butylene terephthalate which polymerizes to polybutylene terephthalate, Fiber-metal laminate component according to one of claims 35 to 38, characterized in that the layer ( 3 ) of the fiber material have tissue and / or scrims and / or nonwovens of fibrous materials, in particular of glass fibers or carbon fibers. Fiber-metal laminate component according to one of claims 35 to 39, characterized in that the metallic material for the sheet-like layers ( 2 . 4 ) Aluminum alloys of the 5XXX and 6XXX series. Fiber-metal laminate component according to one of claims 35 to 40, characterized in that the metallic material for the sheet-like layers ( 2 . 4 ) Steels DC06 and / or DP 600. Fiber-metal laminate component according to one of claims 35 to 41, characterized in that more than two sheet-like layers ( 2 . 4 ) each with the interposition of a layer ( 3 ) of a fiber material to a fiber-metal laminate semifinished product ( 1 ) are layered. Fiber-metal laminate component according to one of claims 35 to 42, characterized in that the layer thicknesses of metallic materials ( 2 . 4 ) and fiber reinforced composite material ( 3 ) are selected depending on the application. Fiber-metal laminate component according to one of claims 35 to 43, characterized in that at least partially more than one layer ( 3 ) of a fiber material stacked one above the other between the metallic layers ( 2 . 4 ) is introduced.

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