For automotive weight reduction, fiber-reinforced thermoplastic polymer (FRTP) is preferred due to its short curing time, good recycling and easy formability of complex parts. Hybrid fiber-reinforced thermoplastic polymer (HFRTP) can take the advantage of two processes (thermo-stamping and injection) and two materials (continuous FRTP and discontinuous FRTP) to form an integrated structure with both complex shape and excellent performance simultaneously. However, the unmatched thermodynamic properties between different materials would produce interfacial residual stress (IRS) as the temperature variation, which will cause the structure separate at the interface and structural warping. This paper would explain the generation mechanism of IRS between thermo-stamping zone of continuous FRTP and injection zone of discontinuous FRTP and investigate the effect of IRS generated during the process on the subsequent load-bearing capacity. The simulation results found that the generation mechanism is that the residual stress of over-molded injection is the superposition of shrinkage stress and thermal stress, which has a negative effect on the mechanical properties.

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