The process chain of a polymer-metal hybrid component used in cars has to be analyzed due to the possibility of unexpected failure during the hydroforming process. The structural component consists of two heat treated extrusion profiles, which are knurled, pre-formed and further processed.

As part of the process analysis, the production chain is subdivided into primary shaping, forming and finishing. The primary shaping involves the analysis of the used materials and their properties, the extrusion process and the subsequent heat treatment. Within the project we monitored the process at the extruders and reviewed the production facilities and the process cycle. In addition, the product and process FMEA were analyzed, evaluated and updated.