Abstract
In this work, the impact response of carbon fibre metal laminates (FMLs) was experimentally and numerically studied with an improved design of the fibre composite lay-up for optimal mechanical properties and damage resistance. Two different stacking sequences (Carall 3–3/2–0.5 and Carall 5–3/2–0.5) were designed and characterised. Damage at relatively low energy impact energies (≤30 J) was investigated using Ultrasonic C-scanning and X–ray Computed Tomography (X-RCT). A 3D finite element model was developed to simulate the impact induced damage in both metal and composite layers using Abaqus/Explicit. Cohesive zone elements were introduced to capture delamination occurring between carbon fibre/epoxy plies and debonding at the interfaces between aluminium and the composite layers. Carall 5–3/2–0.5 was found to absorb more energy elastically, which indicates better resistance to damage. A good agreement is obtained between the numerically predicted results and experimental measurements in terms of force and absorbed energy during impact where the damage modes such as delamination was well simulated when compared to non-destructive techniques (NDT).
Highlights
The drive for high-performance lightweight structures has led to the development of fibre metal laminates (FMLs) [1] made of thin metal sheets combined with fibre reinforcedApplied Composite Materials (2020) 27:511–531 polymers [2]
Carbon fibres/epoxy prepreg combined with aluminium sheets was used as FML, which is named Carbon/aluminium laminates (Carall), instead of glass fibre/epoxy layers used in the commercially developed Glare
A significant advantage of Carall is its extreme efficiency in damage resistance through crack bridging, due to the high stiffness of carbon fibres, which leads to relatively low crack growth rates
Summary
The drive for high-performance lightweight structures has led to the development of fibre metal laminates (FMLs) [1] made of thin metal sheets combined with fibre reinforcedApplied Composite Materials (2020) 27:511–531 polymers [2]. The fibre reinforced composite layers can reduce stresses in metal layers and help to absorb more impact energy compared to monolithic metallic materials when subjected to external impact loading to exhibit a high penetration resistance. Depending on such benefits of mechanical properties improved, FMLs have been widely used for applications in aircraft structures, such as the commercially developed Glare in skin panels for the fuselage of Airbus A380. A significant advantage of Carall is its extreme efficiency in damage resistance through crack bridging, due to the high stiffness of carbon fibres, which leads to relatively low crack growth rates
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