Hybrid manufacturing of sheet metals and functionalizing for joining applications via hole flanging

Abstract Efficient lightweight solutions are of great interest in many industries (aviation, automotive) particularly regarding the limitation CO $$_2$$ 2 -emissions and material waste. An innovative strategy to address these challenges is use hybrid manufacturing. Additive manufacturing (laser metal deposition, LMD) conventional forming methods (hole-flanging) used optimize functionalize AA 6016 sheet parts, which widely car body parts. First all, effects additive reinforcements on mechanical microstructural properties investigated using tensile tests. After reinforced blanks performing subsequent operations, parts damages functionalized through threading. This allows application a bolt connection, tested rip-off tests evaluate effect fracture forces. It can be shown, that manufactured without defects virtually no porosity formability only slightly reduced compared materials. At same time, performance joint enhanced while increase weight limited relatively small amounts.