Hybrid structures
DLR
Hybrid construction methods that combine thermoset and thermoplastic materials offer a fascinating variety of properties and advantages. Thermoset materials such as epoxy resins or polyester resins cure through an irreversible chemical reaction and are characterised by high rigidity, strength and temperature resistance. In contrast, high-performance thermoplastics such as PPS, LM-PAEK and PEEK can be melted and repeatedly moulded without changing their chemical structure and offer flexibility, weldability, ease of processing and recyclability.
The combination of these material classes in hybrid assemblies allows designers to specifically control the desired properties such as strength, stiffness, toughness and temperature resistance. In addition, the advantages of the individual material classes can reduce production complexity. Thermoset production processes are ideal for flat components, while thermoplastic production processes are particularly suitable for complex components that may be produced in large quantities.
By introducing a hybrid boundary layer in the joining area of the components, it is possible to weld thermoplastic and thermoset components together. This offers completely new possibilities in the sequence of aircraft production and system installation, as welding processes are dust-free and can therefore be used when systems such as cables have already been installed.