A new lightweight metal-composite-metal panel for applications in the automotive and other industries

Abstract

A new lightweight metal-composite-metal (MCM) panel is developed. This panel consists of two layers of 0.2-mm thick stainless steel sheet with a layer of woven fabric (semi-flexible composite) in between. The stiffness and the dent resistance of this MCM-panel are compared to those of corresponding panels pressed in 1-mm thick aluminium, 0.8-mm thick carbon steel and 0.8-mm thick stainless steel sheets. Compared to the aluminium panel, the MCM-panel exhibits a slightly smaller stiffness. However, the MCM-panel displays a larger dent resistance than the aluminium and the carbon steel panels. The new panel is 46% heavier than the aluminium panel. However, it is 60% lighter than the carbon and stainless steel panels. This new panel is expected to have many applications in manufacturing of parts for car, train and bus bodies, appliances and household machines. Machine chassis and air cargo containers are other examples of products, in which the new panel can be used. Production of the new panel requires that the tools be heated. The cycle time is short, since a newly developed and patented method for ultra-rapid heating of tools has been used in this study. The production is economical, since the cycle times is short and recycled fibres can be used. The production process is not completely optimized yet. However, the conducted experiments show that the panel stiffness and dent resistance are benefited, if the tool pressure applied during the heating is low.