Process concepts for the manufacturing of hybrid composites made from aluminum and CFRP with a polymer-based decoupling layer

Currently, conventional mechanical or adhesive joining technologies are used for the production of hybrid composites consisting of the light construction materials aluminum (Al) and carbon fiber reinforced polymer (CFRP). A direct joining of these materials is, however, problematic due to their electro chemical in compatibility and the resulting corrosive degradation. The aim of the new collaborative research project “Hybrid Casting” funded by the Deutsche Forschungsgemeinschaft (DFG) is to join Al and CFRP in novel ways using the aluminum high pressure die casting (HPDC) process to create an intrinsic hybrid composite with a decoupling and adhesive layer made from thermoplastic polyether etherketone (PEEK). Two process concepts to produce such a hybrid composite are the primary focus in this investigation