Machbarkeitsuntersuchung zur Herstellung von CFK – Aluminium Verbundgussstrukturen im Sandgussverfahren

Translated title of the contribution: Feasibiltiy study for the production of CFK-Aluminium composites using sand casting

Robert Kleinhans

Research output: ThesisMaster's Thesis

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One oft he moste remarkable keywords in automotive design is manufacturing lightweight components, to fabricate lighter cars and also to give them a rigid structure. For more saftey and comfort, it ist necessary to reduce the weight of newly developed models, in order to reduce fuel consumption. Aluminum became an established material in the automotive industry even several decades ago. In engine construction it could be referred as a standard material. The same is increasingly true for body components and supporting structures. Carbon fibre composits are still the exception, apart from applications in high priced derivates. The combination of aluminum and carbon opens a new dimension of lightweight design with respect to the combination of material properties. The main purpose of this work ist to investigate an alternative for the presently used joining technologie for Carbon fibre and Aluminum. Carbon fibre integrated in cast structures, offer numerous advantages. In combination with sand casting a high degree of freedom can be achieved in the design of components. In order to optimize the sand casting process for this particular task, various criterions had to be investigated. Thus, the cooling rate towards the outer side had to be maximized, and further the heat transfer to the inside oft he inside had to be minimized. This is done firstly by high heat conducting media as metal chills, and secondly, on the inner side, by thermal barrier layers with poor heat transfer. A number of combinations were investigated an a miniature pattern with three mould cavities. In this case, various kinds of moulding materials, heat sinks and ceramic barrier layers were used. Furthermore, the impact of three common aluminum casting alloys were investigated. The findings obtained here were transfered to a component close model, which had structures, as they may occur in vehicle structures. Many questions could be answered in the context of this study, which may be considered as a great step forward towards series maturity oft he process.
Translated title of the contributionFeasibiltiy study for the production of CFK-Aluminium composites using sand casting
Original languageGerman
  • Reimann, Tim, Co-Supervisor (external), External person
  • Schumacher, Peter, Supervisor (internal)
Award date30 Oct 2015
Publication statusPublished - 2015

Bibliographical note

embargoed until 16-10-2020


  • Composite Aluminium-Carbon fibre
  • Aluminum casting
  • sand casting
  • lightweight construction
  • carbon fibre

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