Laser structuring for hybrid lightweight materials

Hybrid lightweight materials as an alternative with great potential

Fiber-reinforced polymers (FRP) have become essential for numerous applications, such as automotive and aerospace industries. However, not all components can be replaced only by FRP composites, as the materials often do not match the requirements for further processing or the later conditions of use. Hybrid components combine the advantages of lightweight FRP composites with those of metal materials. The key challenge is the force-transmitting joint of the FRP and the metal materials, which requires appropriate preparation of the components. This way, mechanically resilient lightweight components for lightweight constructions can be obtained.

Laserbased Microstructuring

To create microscopic undercuts, a structure is implemented into the metallic material with a laser beam. In the following thermal joining process, the created undercuts are filled with the FRP and build a form-fit connection. For maximum weight reduction, the metallic components can be reduced to a minimum thickness of 0.2 mm. Typical metallic materials for hybrid lightweight materials are primarily aluminum alloys and stainless steels. The shape and design of the structures can be individually adapted to the subsequent application.

Our services at a glance

  • Plant and process design for laser scribing
  • Production of prototypes of structured semi-finished metal products with a thickness below 0.2 mm with and without FRP composite
  • Support in material selection, structural design, process development and production planning
  • Material qualification in the laser structuring process
  • Construction of special machines for continuous and stationary laser scribing processes

Stationary or continuous production of fiber-metal laminates

Laser Structuring

Laser radiation is used to apply various structures to thin-walled metals. This improves the surface adhesion between the metallic cover layers and the core material made of fiber composite layers, that will be joined.

Hot pressing of laminate layers

The layers of fiber composite and two cover layers of laser-structured metal are inseparably bonded together in a hot pressing process.

Fiber-metal laminates (FMLs)

FMLs are lightweight, mechanically resilient semi-finished products for numerous products and industries that can be machined by classic metalworking processes. Classic fiber composite materials as well as new, sustainable bio-fiber materials are equally applicable here.