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Injection molding is an economically attractive manufacturing process of short and long fiber-reinforced thermoplastic (TFRP) parts. The benefits in contrast to thermoset resin transfer molding (RTM) processes are the manufacturing of complex geometries in short cycle times. In the automotive sector, injection molding is one of the most common manufacturing processes for semi structural parts e.g. for the frontend, door coverings or functional joining parts. In structural applications, the fiber specifications, volume content, length, material and orientation are influencing the characteristics of strength, stiffness and brittleness. Due to a nearly isotropic material behaviour of short TFRP parts, directional long or endless TFRP are suitable for a load path-oriented design. The load path oriented fibers lead to an anisotropic higher stiffness and strength. The integration of positioned long or endless fibers in the injection molding process and the realization of load transfer between metal and plastic are challenging tasks in present research works. This paper deals with the integration of endless fibers in the injection molding process, focussing on the reinforced interface between metal and thermoplastic parts. The hybridization process and a calculation of the fiber infiltration time are presented. Furthermore, the performance of fiber-reinforced interfaces between metal and thermoplastic parts is characterized in tensile tests. 4th Brazilian Conference on Composite Materials. Rio de Janeiro, July 22nd-25th, 2018

INTEGRAL MANUFACTURING OF PLASTIC-METAL HYBRIDS CONSISTING OF ENDLESS FIBER REINFORCEMENT USING INJECTION MOLDING