Composite Sandwich with Aluminum Foam Core and Adhesive Bonded Carbon Fiber Reinforced Thermoplastic Cover Layer

The combination of metals and fiber reinforced plastics is also known as hybrid metal composites. They offer the fusion of the good static mechanical properties of the fiber reinforced plastics and the good dynamic mechanical properties of the metal. For that reason, parts made of hybrid metal composites are predestined for the use as load relevant parts. The purpose of this study was to develop new technologies for semi finished hybrid metal composite materials. Thermoplastic Fiber-Reinforced Composites (TP-FRC) were arranged with new, isotropic, closed pore Aluminum Foam (AF) structures to an Extrinsically Combined Composite Sandwich (ECCS) by adhesive bonding. They form the basis for novel weight-optimized as well as cost-effective applications. The entire manufacturing process for the continuous semi-finished product was examined and verified according DIN EN 2563. This was done with regard to subsequent characterization by the specific bending modulus and specific bending stiffness. The examinations show a high bending stiffness and high strength structures combined with excellent damping properties at high damage tolerances. These are the most requested in automotive applications.