What is the problem/issue being addressed?
The transport sector is under constant pressure to produce innovative lightweight structural solutions that improve vehicle fuel consumption. Single-material structural components in vehicles can be replaced, advantageously, by layered integrated multimaterial systems. When properly selected and designed these layered composite-metal hybrid materials enable a significant weight reduction and consequently lower CO2 emissions. Transition from an all metal or composite bulk to a multi-layer hybrid metal/composite has already been shown to provide advances in crashworthiness, impact, strength, acoustic and vibrational performance in automotive and aerospace components and assemblies. Despite intensive research and low-volume production, advanced continuous fibre polymer composites still lack truly high-volume applications in the automotive sector. LAY2FORM aims to demonstrate how the integration of novel unconventional technologies, into manufacturing systems provides an efficient, flexible and cost-effective solution for the manufacturing of multifunctional hybrid lightweight materials. The implementation of an end-to-end engineering concept implements a continuous and automated process chain adapted for a mass customisation manufacturing able to handle efficiently a range of material combinations and products (adapted to Industry 4.0 vision).
Why is it important for society?
One of the key societal challenges of today in Europe is its transport-related decarbonisation, from the road transport to the aviation sectors. Over the past few decades, structural design for vehicle structures has been subjected to multiple pressures of different stakeholders focused in decreasing their footprint and in improving their safety towards increased transport efficiency, reduced emissions and life cycle impact of the vehicle on the environment, as well as to improve the safety, performance, functionality, comfort and perceived quality. LAY2FORM results can certainly contribute to the ongoing deep changes on the overall mobility sector, particularly in the current trend of sensor/ actuator-based interaction between the society, the vehicles and the transport infrastructures.
What are the overall objectives?
The main goal of LAY2FORM is to develop a new advanced and highly integrated manufacturing process for forming of layered metal/ thermoplastic-matrix composite hybrid materials, suitable to highly dynamic and competitive manufacturing environments, such as those of the automotive sector. Unconventional technologies (laser and Ultrasound-US) will be integrated into the manufacturing route, for material modification, adhesion, shaping, spot welding and consolidation, as well as for end-of-life material disassembly. The innovative integrated process will be assisted with simulation, cognitive automation, decision support, real-time control and advanced in-line NDT techniques, in a fully automated multi-stage manufacturing system. Forming of metal foil / carbon fibre reinforced thermoplastic hybrids will be demonstrated in industrially relevant conditions.
