Manufacturing and Investigation of Steel-CFRP Hybrid Pillar Structures for Automotive Applications by Intrinsic Resin Transfer Moulding Technology

Automotive lightweight design can be achieved by the combination of sheet metal and carbon fibre-reinforced plastic (CFRP). The hybrid structure enables a simultaneous usage of the specific advantages of both materials. This paper is focused on basic technological investigations in the field of manufacturing of hybrid structures by utilising the intrinsic RTM technology. Initially, the production process of automotive pillar structures in a steel-CFRP hybrid design is exemplified by an omega profile. Further, the viscosity measurement is carried out to identify the curing properties of the deployed epoxy matrix system used. Finally, the results of four-point bending tests and crash tests on hybrid omega profiles are presented, analysed and evaluated. It could be shown that the mechanical properties in the bottom area and the flank area are consistent. Additionally, hybrid materials exhibit a satisfying weight-saving potential for automotive structural components comparing pure steel structures.