Application Center for Wood Fiber Research HOFZET®

Research project

Load-bearing, crash-relevant metal/fiber-reinforced plastic assembly for passenger cars (EnTraHyb)

In collaboration with two further Fraunhofer Institutes as well as three institutes from the Technische Universität Braunschweig, we at the Fraunhofer WKI Application Center for Wood Fiber Research HOFZET are developing a load-bearing, crash-relevant metal/fiber-reinforced plastic assembly for application in automobiles. Within the scope of this project, the intelligent combination of different materials and production processes also enables us to demonstrate the lightweight construction potential for crash-relevant components. For this purpose, we are utilizing new process routes and synergy effects within the framework of the Open Hybrid LabFactory e. V. The overall objective of the project is the development of a generic interface component for the load-compliant joining of fiber-reinforced plastics and metals on the basis of a cast node. 

© Fraunhofer IFAM
Hybrid small-scale specimen, produced using aluminum low-pressure die casting, TP-FRP thermoforming and PA6 injection molding with continuous fibers.

Within the framework of the project, the Fraunhofer WKI is integrated in a diverse spectrum of developments and processes, from the selection of the materials through the process itself and on to the final component. At the HOFZET, we examine individual process steps through material testing by means of computed tomography (CT) and adjust the process according to the knowledge obtained. Our main focus within the scope of the EnTraHyb project is placed upon the development and evaluation of appropriate end-of-life and new-life concepts for the component which is to be developed. The direct bonding of the fiber-reinforced plastic with an aluminum alloy results in material combinations which cannot be separated from one another, or only with considerable effort. For this reason, recycling concepts are being developed not only for the pure individual materials, which are accrued, amongst other things, as cuttings and similar items during the process, but also for the material combinations. We view a mechanical recycling with subsequent reuse in various processes as minimal recycling. An important role is, however, also played by other approaches such as chemical recycling or pyrolysis. 

Projekt partners

  • Fraunhofer IFAM (leadership)
  • Fraunhofer IWU
  • Technische Universität Braunschweig (ifs, IK, IWF)

Funding

Funding body: Niedersächsisches Ministerium für Wissenschaft und Kultur (Ministry for Science and Culture of Lower Saxony, MWK)

Projetc coordinator: Fraunhofer IFAM

Duration: 1.9.2014 to 31.8.2018