Process and Bonding Modification for Media-based Forming of Complex Continuous Fiber Reinforced Hybrid Parts: Presentation held at ITHEC 2020, 5th International Conference and Exhibition on Thermoplastic Composites, 13-15 October 2020, Virtual Editio

This article describes the modification of combined processes which merge injection molding and media-based forming to produce lightweight hybrid structures, saving resources compared to separate processes in sequential order. A tube-based process combination of internal high pressure forming, using gas as pressure medium and injection molding, was investigated. Endless fiber reinforced tubes could be processed this way for the first time in a manner suitable for large-scale production. To support the process modification a numerical approach is created. For this purpose, the failure mode concept according to Cuntze was modified for the three-dimensional stress state to analyze possible failure and leakage. The quality of combination is evaluated via bonding strength and compared to metal-polymer hybrids.