Using a modified pultrusion process, fiber reinforced plastic (FRP) profile structures are functionalized with a metallic surface layer during the ongoing process. The metallic surface layer improves the joining of FRP profiles with other metallic structural components. A novel economic alternative is created for the substitution of pure metallic structural components by lighter hybrid components.

The presentation will first provide an insight into the development oft he modified pultrusion process and production of the hybrid profile components. Compared to classic pultrusion with pure FRP, the production of hybrid FRP-metal profiles requires several special design and process engineering features. Essentially, the presentation will focus on the property and design potentials of the hybrid profile structures for multi-material lightweight design. For example, the integrated metal semi-finished products are coated in advance with a special powder coating to ensure covalent bonding to the FRP component. A validation study showed adhesion strengths at the interface between metal and FRP in the range of 30 to 35 MPa, which can be classified as significantly higher than conventional adhesive joints. Various coating systems and manufacturing influences on bond adhesion were investigated. In addition, the laser welding process was validated as an alternative subsequent joining option for the intersectoral and economical use of the pultrusion profiles. In the further development of the project, the basic knowledge will be transferred to a concrete application example from the field of rail vehicle design.