Novel Process Approach for in-situ Insertion of Functional Elements in RTM-Applications

Lightweight design in vehicles leads to an increasing use of fibre-reinforced-plastics (FRP). To ensure the possibility of detachable joints in those constructions specific joining technologies have to be developed. Available technologies are not suitable for mass production or are leading to damage in the FRP. The aim of this paper is to show the possibilities and the general feasibility of a new process approach for the application of functional elements in FRP or hybrid materials during resin transfer moulding (RTM) processes. Therefore the movement of the RTM-tool-punch is utilised to produce an interlock between the splay stud and the fibres of the non-consolidated preform. This enables the application of the elements during the RTM-process. The resin infusion leads to the consolidation of the CFRP and a further fixation of the splay stud. Pull-out-tests as well as torsion tests are showing the mechanical performance of the joints.