Herstellung verbundverstärkter aluminiumprofile für ultraleichte tragwerke durch strangpressen

Abstract

Due to similar specific properties of aluminum and steel regarding stiffness and mechanical strength only minor achievements as to their application in lightweight space-frame structures can be attained by substituting one material for the other. Only the usage of carbon fibre materials or high performance steels promises a weight reduction as to the application of pipes and profiles in ultra-lightweight structures. At the Chair of Forming Technology of the University of Dortmund a process has been developed which is suitable for the manufacturing of continuously reinforced profiles by means of a modified direct extrusion process. Starting from conventional aluminum billets, various continuously reinforcing elements are being embedded in the wall thickness of the profile matrix. For this process, which is being investigated in the context of the Collaborative Research Centre SFB/TR10, new extrusion dies have to be developed. During experimental studies on a 2.5 MN laboratory direct extrusion press first reinforced profiles were manufactured successfully. In order to improve the understanding of the process and to predict the efficiency of new tool concepts, FEM simulations were carried out simultaneously. Reinforced straight profiles produced with the help of this method cannot be bend due to possible damages to the microstructure. However, in combination with the process of Rounding During Extrusion, which also has been developed at the Chair of Forming Technology, these reinforced orofiles will be producible with a curved contour as well. © 2004 WILEY-VCH Verlag GmbH & Co. KGaA.