Forming of hybrid material systems

Hybrid material systems offer a wide range of advantages, e.g. with regard to the reduction of CO2 emissions. In order to be able to manufacture components cost-effectively in an industrial environment from these innovative materials, the technical know-how is still lacking. In order to obtain this know-how, research work is currently in progress at LUF within the HyOpt project.

The aim of the research project is the development of optimization-based CAE methods and flexible manufacturing processes for the design and manufacturing of load and forming compliant hybrid materials with tailored properties. Hybrid materials are defined here as a combination of fiber-reinforced plastics and thin metallic sheets. The central innovation within this project is the development of a toolbox for the design of new hybrid materials consisting of a software solution for the optimization-based design of the material structure and adaptable smart manufacturing processes for their production and further processing into lightweight components.

A material development based on a top-down approach enables the exploitation of new, as yet unused, lightweight potentials by combining conventional materials in a way that is suitable for the demands. However, the consistent transfer of the multi-material approach to the thickness and surface direction of components requires a holistic approach. In addition to the base materials, this also includes corresponding surface properties and adhesion promoter systems, ecological aspects, economic efficiency, and social acceptance.

In order to address these questions, the project also focuses on social and economic science, investigating the risk and benefit perceptions of various social stakeholder groups and analyzing the conditions under which novel hybrid materials meet with acceptance or rejection in society and the assumptions and arguments underlying these opinion-forming processes.