Enhancement of thin hot-stamped components using fiber-reinforced plastic structures with improved fatigue strength characteristics

authored by: Bernd Arno Behrens, Sven Hübner, Denis Fink, Timo Fünfkirchler, Jörn Wehmeyer, Klaus Dilger, Sven Hartwig, Christian Gundlach
Abstract: The automotive industry has high demands for multi-material structures in achieving lightweight design, efficient body construction and enhanced functionality. These structures capitalize on the favorable mechanical properties and reduced weight of such combinations, especially when metal and plastic are integrated to create a synergistic effect. This research paper outlines the advancement of a hot-stamp and an compression tool to facilitate a thermally assisted compression process. This process enables the seamless joining of GMT (Glass Mat reinforced Thermoplastics) and 22MnB5 steel without the need for additional bonding agents. In the initial step of the process, a hot-stamping tool is utilized to fabricate cap profile components. Afterwards a combined compression and joining process of the GMT takes place. Through adhesion, the GMT material bonds to the rough surface of the AlSi-coated 22MnB5, enabling the removal of the final component. The influence of process parameters was assessed through static and dynamic tests conducted on demonstrator components. Overall, it was determined that the introduction of a GMT stiffening structure leads to improvements in both the static and dynamic properties of the component so a reduction of the steel thickness of the structure can be carried out. This reduction in thickness is accompanied by a decrease in the mass of the test structure, while maintaining or even enhancing its static and dynamic properties. Further weight savings are possible through additional component and process optimization.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
External Organisation(s): Technische Universität Braunschweig
Type: Conference article
Journal: Procedia CIRP
Volume: 131
Pages: 125-129
No. of pages: 5
ISSN: 2212-8271
Publication date: 2025
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Control and Systems Engineering, Industrial and Manufacturing Engineering
Electronic version(s): https://doi.org/10.1016/j.procir.2024.09.020 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{ed3ddd8f8d1b45ecb4cc457560cdfb45,
title = "Enhancement of thin hot-stamped components using fiber-reinforced plastic structures with improved fatigue strength characteristics",
abstract = "The automotive industry has high demands for multi-material structures in achieving lightweight design, efficient body construction and enhanced functionality. These structures capitalize on the favorable mechanical properties and reduced weight of such combinations, especially when metal and plastic are integrated to create a synergistic effect. This research paper outlines the advancement of a hot-stamp and an compression tool to facilitate a thermally assisted compression process. This process enables the seamless joining of GMT (Glass Mat reinforced Thermoplastics) and 22MnB5 steel without the need for additional bonding agents. In the initial step of the process, a hot-stamping tool is utilized to fabricate cap profile components. Afterwards a combined compression and joining process of the GMT takes place. Through adhesion, the GMT material bonds to the rough surface of the AlSi-coated 22MnB5, enabling the removal of the final component. The influence of process parameters was assessed through static and dynamic tests conducted on demonstrator components. Overall, it was determined that the introduction of a GMT stiffening structure leads to improvements in both the static and dynamic properties of the component so a reduction of the steel thickness of the structure can be carried out. This reduction in thickness is accompanied by a decrease in the mass of the test structure, while maintaining or even enhancing its static and dynamic properties. Further weight savings are possible through additional component and process optimization.",
keywords = "Advanced/smart materials, lightweight structures, multi-material concepts/solutions",
author = "Behrens, {Bernd Arno} and Sven H{\"u}bner and Denis Fink and Timo F{\"u}nfkirchler and J{\"o}rn Wehmeyer and Klaus Dilger and Sven Hartwig and Christian Gundlach",
note = "Publisher Copyright: {\textcopyright} 2025 The Author(s).; 3rd CIRP Conference on Composite Material Parts Manufacturing, CCMPM 2024 ; Conference date: 25-09-2024 Through 27-09-2024",
year = "2025",
doi = "10.1016/j.procir.2024.09.020",
language = "English",
volume = "131",
pages = "125--129",
journal = "Procedia CIRP",
issn = "2212-8271",
publisher = "Elsevier BV",
}