Lightweight design is a key element for sustainable transport but is experiencing massive resistance in shipbuilding due to inadequate joining technologies for fibre-reinforced composites and steel. The research project Hybride Fügetechnologie für Verbindungen im maritimen Einsatz (or Hy-FiVE) – (translated as Hybrid Joining Technology for Joints in Maritime Applications), is developing new technologies and evaluating them for maritime applications. Adhesive bonding, as the standard method for joining lightweight structures made of fibre-reinforced plastics (FRP) and metal structures, often does not meet the time and cost requirements of shipbuilding in terms of design, certification and production. The aim is therefore to develop new and efficient adhesive-free joining technologies for FRP and metal applications.
The project partners
The eight partners (five industrial companies and three scientific institutions) in the project represent the entire spectrum along the value chain, from textile and material manufacturers, engineering offices such as ar engineers to manufacturing companies. They are supported by three scientific institutions with their expertise in the field of fibre and FRP technology, as well as in the field of welding. They are supported by three scientific institutions with their expertise in the field of fibre and FRP technology, as well as in the field of welding.
The application in shipbuilding is the focus of the HyFiVE research project. Thus, an essential aspect of the project is the development of the technologies in line with the requirements in shipbuilding. This includes, among other things, integration into FRP components using different manufacturing methods, scalability, non-destructive testing, as well as fire protection. To this end, the consortium works closely with shipyards and classification societies.
Dealing with the following topics, ar engineers is making an important contribution to the success of the HyFiVE project:
- Structural evaluation of novel joining concepts for steel-GFRP hybrids.
- Development of design and calculation methods for the hybrid connector FAUSST
- Carrying out extensive numerical simulations for the mechanical characterisation of the complex 3D-structure of FAUSST
- Comparison of the mechanical performance with conventional joining methods (adhesive bonding, rivets, screws)
Development of standardisable design and verification processes of steel-GFRP hybrid structures with FAUSST connectors for use in shipbuilding assemblies. Optimisation of the joining technology from a structural point of view in order to improve the mechanical performance in the context of the global assembly.
The following competences at ar engineers are being used and further developed in this research project:
- Extensive experience in conceptual design and coordination of complex projects
- Many years of expertise in lightweight design – also in shipbuilding applications
- Best possible representation of complex boundary conditions through numerical simulation
- Component optimisation in the context of innovative material compositions, such as the FAUSST hybrid connector
- Experience in cooperation and project management with certification bodies
With open minds, we will map and optimise disruptive techniques such as hybrid material combinations through the use of high-end simulation tools; our in-depth understanding of shipbuilding applications makes possible an early proof of concept based on the theoretical findings. This will enable us to provide important impulses for optimising this innovative joining technology.
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Head of Engineering
Background: M.Sc. Aeronautical Engineering with a focus on Simulation & Composites
Fabian’s favourite project:
I think it’s cool to explore new areas of material science.
I’m excited that the project brings together many partners from different branches of industry and research all over Germany. The frequent exchange in the consortium results in new scientific findings as well as new opportunities for industrial cooperation beyond this research project. The degree of innovation of this project is very high: the joining technology developed with FAUSST is a pioneer for disruptive engineering and a benchmark for new design concepts for composite and hybrid structures in shipbuilding.
I can contribute and expand my expertise in the use of high-end simulation tools, as the intensive research of complex material behaviour requires extensive 3D simulation paired with experimental validation. This takes me into new areas of materials research and allows me to develop new calculation methods for innovative material combinations. I can then use this acquired know-how profitably for our customers at ar engineers.
Development & Calculation Engineer
Background: M.Sc. Mechanical Engineering with a focus on plastics technology
Luiz’ favourite project:
For me, it is exciting to research the further development of state-of-the-art simulation techniques.
Participating in the HyFiVE project is very interesting for me from several aspects.
One of them is that we use state-of-the-art simulation technologies to perform the required calculations. This allows us to better understand this new technology at different levels, from micro to macro scale. It also helps to improve our know-how in the field of fibre composite structures.
Another aspect for me is the knowledge transfer between the project partners. The heterogeneous consortium offers expertise in all important areas of material research and technology development: material suppliers, experimental testing, joining technology, calculation & simulation, technical textiles and component manufacturing. As the project partners cover the entire spectrum of services, it is possible for me to better understand the different development phases of this new technology and to contribute my share to the success of the project.