Topologieoptimierter Verbund von Aluminium und Stahl zur lokalen Steifigkeitserhöhung von Druckgussbauteilen

Under the premises of weight and stiffness a multiphase optimization is used to shape a longitudinal carrier in a hybrid aluminum - steel design. Goal is to retain the function despite reduced dimensions. Therefore a steel core is integrated via die casting to increase the bending stiffness. Compared to an aluminum design with reinforcing cast ribs, the simulation of the composite reaches the same stiffness without local rips. Under real tests the composite shows an enhancement in stiffness, however can't compare with the monolithic aluminum component. Main reason for that is the required jacketing and the thus thermally induced residual stresses in the cast matrix that leave the aluminum already plasticized. Under certain volume ratio a reinforcement can be achieved, however under an inferior relation between performance and weight compared to monolithic constructions. Therefore the implementation of such composite component has to be assessed under lightweight facets. The developments of the hybrid aluminum - steel longitudinal carrier provide a base for a new way of construction for cast parts that is able to cause a scalable reinforcement without increasing the part dimensions.