Abstract
Lightweight design offers a reduction of local emissions and increase the range and handling dynamic of automobiles while driving. With a 40% share of the total vehicle mass, the body-in-white, consisting of high-strength steel materials, is a significant lever for weight reduction, but it is reaching its limits as the sheet thickness is further reduced, especially in crash-relevant structures such as A- or B-pillars, bumper cross beams e.g. (Friedrich in Leichtbau in der Fahrzeugtechnik, Springer, ATZ/MTZ-Fachbuch. Wiesbaden, 2017; Liu et al. in Int. J. Adv. Manuf. Technol. 69:211–223, 2013). An alternative approach are hybrid structures made of a combination of fibre-reinforced plastics (FRP) and metal sheets. The standard metal components can be improved by the targeted use of FRP in many ways. It enables a production of completely new components with increased performance and higher level on functional integration. This paper describes the transition of a lower A-pillar of a high-volume segment vehicle by showing the changeover from the monolithic steel design to the hybrid plastic-metal design. Therefore, the conceptual design of the component and its production are explained.
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Acknowledgements
The authors would like to thank the institute directors Prof. Dr.-Ing. Thomas Vietor (IK), Prof. Dr.-Ing. Klaus Dröder (IWF) and Prof. Dr.-Ing. Klaus Dilger (ifs) as well as the partners of Volkswagen AG, Thyssenkrupp Steel Europe AG and BASF SE for supporting and financing the multilateral project “Use of organically coated semi-finished sheet metal products for multi material lightweight applications”.
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Bader, B., Berlin, W., Demes, M. (2021). Interdisciplinary Research for the Development and Realization of a Structural Component in Multi-Material Design Suitable for Mass Scale Production. In: Dröder, K., Vietor, T. (eds) Technologies for economic and functional lightweight design. Zukunftstechnologien für den multifunktionalen Leichtbau. Springer Vieweg, Berlin, Heidelberg. https://doi.org/10.1007/978-3-662-62924-6_2
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DOI: https://doi.org/10.1007/978-3-662-62924-6_2
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