Abstract
This paper presents a novel technique for improving aluminium–glass/epoxy composite interfacial bonding through the generation of metallic nano-architectures on the metal surface. Silver nanowires (AgNWs) deposited via solution casting at varying concentrations and annealed at different temperatures in an air atmosphere improved the aluminium-glass/epoxy composite fracture toughness as measured via mode I experiments. For AgNW concentrations of 1 and 3 g/m2 deposited via a single-stage process and annealed at 375 °C, the initiation fracture toughness of the aluminium-glass/epoxy composite improved by 86% and 157%, respectively, relative to the baseline composite without AgNWs. The corresponding steady-state fracture toughness of these nano-modified fibre metal laminates (FMLs) were at least seven times greater than the baseline composite. The FML variant in which AgNWs were deposited at a concentration of 3 g/m2 through a two-stage process followed by annealing at 375 °C and 300 °C, respectively after each deposition, achieved the highest steady-state fracture toughness of all nano-modified composites—a fracture toughness value that was 13 times greater than the baseline composite. Intrinsic and extrinsic toughening mechanisms dictated by the morphology of the silver nano-architectures were found to be responsible for the improved initiation and steady-state fracture toughness in nano-modified FMLs.
Highlights
Aluminium alloys and fibre-reinforced polymer (FRP) composites account for the greatest proportion of materials used in the aerospace industry
It is noteworthy that the dissimilarities in the aluminium surface features due to varied deposition processes should allow for tuneable fracture toughness properties at the metal–FRP composite interface
In instances where the AgNWs were oriented normal to the aluminium sheet, they were expected to contribute to improved metal–FRP laminate fracture toughness as demonstrated by Nguyen and others [23,24] for hybrid metal-composite joints with integrated 3D-printed metallic reinforcements
Summary
Aluminium alloys and fibre-reinforced polymer (FRP) composites account for the greatest proportion of materials used in the aerospace industry They offer high-impact resistance, aluminium alloys are susceptible to stress-corrosion cracking which can lead to unexpected sudden failure of components subjected to tensile loading [1]. The certification of the glass reinforced aluminium laminate, commercially identified as GLARE® for use in the Airbus380 upper fuselage demonstrates technological maturity and economic viability of FML composites in aerospace engineering Despite their desirable characteristics, the durability and continuing airworthiness of FML composite structures is strongly linked to the interfacial strength between the metal sheets and FRP laminates [4,5,7]. It is critical to develop technologies that can improve the interfacial adhesion between the metal and FRP composite layer
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