Technologies for Lightweight Structures (TLS) 2021-05-16T11:57:54+02:00 Prof. Dr. Lothar Kroll Open Journal Systems <p><em>Technologies for Lightweight Structures (TLS)</em> is a peer-reviewed, open access journal that publishes original research articles as well as review articles in the field of multifunctional lightweight structures.</p> <p><em>Technologies for Lightweight Structures</em> is aimed at experts from academia and industry who contribute their knowledge to the research and development of lightweight structures and of the corresponding manufacturing technologies. Thus, it serves to increase the unrestricted, interdisciplinary flow of knowledge between users, manufacturers, designers and researchers involved in the promotion of these innovative key-technologies.</p> <p>The journal's main language is English, but submissions in German are also welcome.<br> In order to address a national and international readership alike, submissions in German are professionally translated into English as a journal service after acceptance.<br>Please see our <a href="/about/submissions">Author Guidelines</a> for information on article submission.</p> <p><a href="/about/">More about the journal</a></p> Technology fusion of metal injection moulding and selective laser melting for the manufacture of complex and multifunctional (hydraulic) components 2021-05-16T11:57:54+02:00 Martin Herold Camilo Zopp Oliver Neiske Frank Schubert Jan Hustert Wolfgang Nendel Lothar Kroll <p>Selective laser melting (SLM) and metallic injection moulding (MIM) are established processes for the production of high-performance metallic components for small and large series. In the aerospace industry, where very high demands are placed on materials and components, both processes are still considered to be relatively new. In both processes, the conventional titanium alloy Ti-6Al-4V can be used in the form of powder. Currently, both technologies are only considered separately. By fusing components of the same type, multifunctional components with a high lightweight construction potential can be produced.</p> <p>In order to generate direct material fusion, the MIM component must be mechanically processed accordingly. In addition, suitable SLM process parameters must be developed in order to ensure both generative construction and high joint strength. To this end, a characterisation of the joining zone and the static joint strength was carried out. Furthermore, pressure test samples were designed and examined both statically and for fatigue strength. Thus, a high static joint strength could be proven. The compression test samples also withstood a fatigue strength of over 1 million cycles.</p> 2020-12-10T15:15:21+01:00 ##submission.copyrightStatement## Multifunctional FRP-Aluminum Foam Production Setup for Battery Housings of Electric Vehicles 2021-05-16T11:57:54+02:00 Rico Schmerler Tobias Gebken Markus Kühn Welf-Guntram Drossel Klaus Dröder Carsten Lies <p>The battery systems of electrified vehicles are characterized by increasing weight due to larger battery modules. A lightweight battery carrier structure can reduce the system weight by replacing heavy metallic housing components with materials such as fiber-reinforced plastics (FRP) and aluminum. The battery housing must meet several requirements, e.g. stiffness, crash and intrusion protection and thermal management.</p> <p>Today’s battery housings are manufactured using die-cast or extrusion parts and are actively cooled. A novel approach is a lightweight hybrid battery housing consisting of a thermoformed FRP as a stiff outer shell and an integrated closed-cell aluminum foam infiltrated with phase change material (PCM) for passive thermal management. This multi-material structure enables the substitution of functionally separated systems in one intelligent solution.</p> <p>In the Open Hybrid LabFactory an entire process chain was established, including the aluminum foaming process, the thermoforming of FRP with heating and consolidating as well as the integrated forming and joining process of FRP with aluminum foam.</p> <p>With the goal of application-oriented research, a battery housing of an existing electric car was used to define requirements such as design space and mechanical specifications. Based on parameter studies an optimized process design was achieved, which is described in this paper.</p> 2020-12-21T16:28:21+01:00 ##submission.copyrightStatement## Analytical modelling of continuous fibre-reinforced thermoplastics’ thermomechanical properties and implementation into a failure model 2021-05-16T11:57:51+02:00 Norbert Schramm Jan Xaver Teltschik Lothar Kroll <p>Mechanical properties of fibre-reinforced thermoplastics show a remarkable temperature dependence within application temperatures of automotive and aerospace lightweight structures. To take this dependence into account when designing components, the strengths (, , , , ) and stiffnesses (, , , , ) of continuous carbon and glass fibre-reinforced polyamide 6 and glass fibre-reinforced polypropylene are modelled analytically based on experiments. Data from temperature-controlled tests on flat samples in the range from -20&nbsp;°C to +80&nbsp;°C are therefore approximated using an extended hyperbolic approach. The models obtained are then evaluated based on their deviation from the experimental values. The main criterion of this evaluation is the reliable prediction of the temperature-dependent material properties while minimising the effort for generating test data and determining model parameters. Furthermore, the failure behaviour of the investigated materials under multiaxial mechanical and thermal stress is examined by implementing the determined strength curves into Cuntze’s physically based failure criterion.</p> 2021-05-07T11:34:06+02:00 ##submission.copyrightStatement##