In consideration of environmental aspects and limited availability of resources, the fo-cus of automotive and aerospace industry is on significant weight optimization espe-cially for moved masses. In this context, innovative lightweight materials as well as material combinations need to be developed. A considerable potential for lightweight structures can be found in fibre- or textile-reinforced semi-finished products. Due to their specific characteristics and extraordinary structural diversity, thermoset and ther-moplastic matrix systems can be used. In particular, carbon fibres as reinforcing com-ponent combined with a thermoplastic matrix polymer are able to establish new high-performance applications. Besides the significant lightweight characteristics of the fi-bre-plastic-composites, partly contrary requirements must be satisfied in many areas, such as strength and ductility. In this field, the combination of fibre-reinforced polymers with aluminium or titanium sheets creates unique composites materials, so called hy-brid laminates, which fulfil the expectations.
The focus of the current study is on the new development of a thermoplastic hybrid laminate named CATPUAL (CArbon fibre-reinforced Thermoplastic PolyUrethane/AL-uminium laminate). The structure of the laminate is an alternating sequence of thin aluminium sheets (EN AW 6082-T4) and fibre-reinforced thermoplastic polyurethane (TPU). The individual layers are consolidated to each other by using hot pressing pro-cess. First results showed that the impregnation capability of thermoplastic polyure-thane surpasses any other commercially available hybrid laminates. Furthermore, the mechanical properties regarding bending strength and interlaminar shear strength are exceeding the state of the art drastically.