New Method Connects CFK and Aluminum – HyFKAl Project Launched

Fraunhofer IFAM and the Faserinstitut Bremen e.V. are collaborating on a new project called "HyFKAl," which aims to develop an innovative hybrid casting process for joining CFK (carbon fiber-reinforced plastic) and aluminum. This method is designed to enable SMEs to produce cost-effective, large-scale hybrid CFK-aluminum components.

Hybrid casting for joining CFRP and aluminum, © Fraunhofer IFAM

Opportunities for Lightweight Construction and the Mobility Sector

Lightweight structures are crucial for reducing CO2 emissions. Multimaterial designs using CFK and metal can significantly reduce energy consumption through efficient material use. The mobility sector, including automotive and aerospace industries, stands to benefit greatly from such innovations. However, traditional joining techniques present challenges, such as contact corrosion, increased weight from additional joining elements, and reduced strength due to drilling.

Innovative Approach of the Hybrid Casting Process
The HyFKAl project’s hybrid casting process integrates CFK components directly into the aluminum die-casting process. The goal is to develop an economical method for joining CFK and aluminum, fusing thermoplastic and thermoset CFK structures with aluminum.

Project Responsibilities

Fraunhofer IFAM: Responsible for the die-casting technology, including temperature and parameter control, as well as the design and modeling of the transition area between aluminum casting and fiber composite components.
Faserinstitut Bremen e.V.: Focuses on process development in the fiber composite area and the design of insulating layers to protect the fiber composite from thermal impact during the die-casting process.

For more information and contact details, please visit:Fraunhofer IFAM Hybrid Casting CFK-Aluminum