Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 31100
Large-Scale Production of High-Performance Fiber-Metal-Laminates by Prepreg-Press-Technology

Authors: Christian Lauter, Corin Reuter, Shuang Wu, Thomas Troester


Lightweight construction became more and more important over the last decades in several applications, e.g. in the automotive or aircraft sector. This is the result of economic and ecological constraints on the one hand and increasing safety and comfort requirements on the other hand. In the field of lightweight design, different approaches are used due to specific requirements towards the technical systems. The use of endless carbon fiber reinforced plastics (CFRP) offers the largest weight saving potential of sometimes more than 50% compared to conventional metal-constructions. However, there are very limited industrial applications because of the cost-intensive manufacturing of the fibers and production technologies. Other disadvantages of pure CFRP-structures affect the quality control or the damage resistance. One approach to meet these challenges is hybrid materials. This means CFRP and sheet metal are combined on a material level. Therefore, new opportunities for innovative process routes are realizable. Hybrid lightweight design results in lower costs due to an optimized material utilization and the possibility to integrate the structures in already existing production processes of automobile manufacturers. In recent and current research, the advantages of two-layered hybrid materials have been pointed out, i.e. the possibility to realize structures with tailored mechanical properties or to divide the curing cycle of the epoxy resin into two steps. Current research work at the Chair for Automotive Lightweight Design (LiA) at the Paderborn University focusses on production processes for fiber-metal-laminates. The aim of this work is the development and qualification of a large-scale production process for high-performance fiber-metal-laminates (FML) for industrial applications in the automotive or aircraft sector. Therefore, the prepreg-press-technology is used, in which pre-impregnated carbon fibers and sheet metals are formed and cured in a closed, heated mold. The investigations focus e.g. on the realization of short process chains and cycle times, on the reduction of time-consuming manual process steps, and the reduction of material costs. This paper gives an overview over the considerable steps of the production process in the beginning. Afterwards experimental results are discussed. This part concentrates on the influence of different process parameters on the mechanical properties, the laminate quality and the identification of process limits. Concluding the advantages of this technology compared to conventional FML-production-processes and other lightweight design approaches are carried out.

Keywords: Composite Material, Fiber Metal Laminate, lightweight construction, large-series production, Prepreg press technology

Digital Object Identifier (DOI):

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1335


J. C. González Palencia, T. Furubayashi, and T. Nakata, “Energy use and CO2 emissions reduction potential in passenger car fleet using zero emission vehicles and lightweight materials,” Energy, vol. 48, no. 1, pp. 548–565, Dec. 2012.
[2] G. Kopp, E. Beeh, R. Schöll, A. Kobilke, P. Straßburger, and M. Kriescher, “New Lightweight Structures for Advanced Automotive Vehicles - Safe and Modular,” Procedia - Soc. Behav. Sci., vol. 48, pp. 350–362, 2012.
[3] M. Goede, “Karosserieleichtbau als Baustein einer CO2-Reduzierungsstrategie,” 2007.
[4] A. Horoschenkoff, “Statt Stahl und Aluminium,” Kunststoffe, no. 5, pp. 50–54, 2010.
[5] S. Grasser, “Composite-Metall-Hybridstrukturen unter Berücksichtigung großserientauglicher Fertigungsprozesse,” presented at the Symposium Material Innovativ, Ansbach, 2009.
[6] C. Lauter, T. Krooß, and T. Tröster, “Manufacturing of Hybrid Structures by Prepreg Press Technology,” presented at the 19th International Conference on Composite Materials, Montreal, 2013.
[7] W. Homberg, J. Dau, and U. Damerow, “Combined Forming of Steel Blanks with Local CFRP Reinforcement,” presented at the 10th International Conference on Technology of Plasticity, 2011.
[8] C. Lauter, M. Sarrazin, and T. Tröster, “Joining technologies for hybrid materials consisting of sheet metal and carbon fibre reinforced plastics,” presented at the 1st International Conference of the International Journal of Structural Integrity, Porto, 2012.
[9] C. Lauter, J. Niewel, and T. Tröster, “Quasistatic and crash tests of steel-CFRP hybrid pillar structures for automotive applications,” Int. J. Automot. Compos., vol. 1, no. 1, pp. 52–66, 2014.
[10] C. Lauter, Z. Wang, I. Koke, and T. Tröster, “Influences of process parameters on the mechanical properties of hybrid sheet metal-FRP-composites manufactured by prepreg press technology,” presented at the 20th International Conference on Composite Materials, Kopenhagen, 2015.
[11] “DIN EN 1465: Klebstoffe. Bestimmung der Zugscherfestigkeit von Überlappungsklebungen,” 2008.
[12] “Betamate 1620. Crashstabiler Strukturklebstoff. Technisches Datenblatt,” 2006.
[13] N. Asnafi, G. Langstedt, C. H. Andersson, N. Östergren, and T. Hakansson, “A new lightweight metal-composite-metal panel for applications in the automotive and other industries,” Thin-Walled Struct., vol. 36, pp. 289–310, 2000.
[14] T. Sinmazçelik, E. Avcu, M. Ö. Bora, and O. Çoban, “A review: Fibre metal laminates, background, bonding types and applied test methods,” Mater. Des., vol. 32, no. 7, pp. 3671–3685, Aug. 2011.
[15] H. C. Schmidt, U. Damerow, C. Lauter, B. Gorny, F. Hankeln, W. Homberg, T. Tröster, H. J. Maier, and R. Mahnken, “Manufacturing processes for combined forming of multi-material structures consisting of sheet metal and local CFRP reinforcements,” Key Eng. Mater., vol. 504–506, pp. 295–300, 2012.
[16] “DIN EN ISO 527-1: Kunststoffe. Bestimmung der Zugeigenschaften. Teil 1: Allgemeine Grundsätze,” 1996.
[17] “DIN EN ISO 527-4: Kunststoffe. Bestimmung der Zugeigenschaften. Teil 4: Prüfbedingungen für isotrop und anisotrop faserverstärkte Kunststoffverbundwerkstoffe,” 1997.
[18] “DIN EN ISO 527-5: Kunststoffe. Bestimmung der Zugeigenschaften. Teil 5: Prüfbedingungen für unidirektional faserverstärkte Kunststoffverbundwerkstoffe,” 1997.
[19] “DIN EN 2562: Luft- und Raumfahrt. Kohlenstoffaserverstärkte Kunststoffe. Unidirektionale Laminate. Biegeprüfung parallel zur Faserrichtung,” 1997.