This study reports the findings on the impact behaviour of metal-composite structures. Carbon fibre/Epoxy composite laminates were manufactured by using the Automated Fibre Placement (AFP) technique. Subsequently, hybrid structures were fabricated by bonding fibre laminate and aluminium plate together. The hybrids were tested at low velocity impact energies to probe the role of AFP composite laminates on the performance of the hybrid system. Our findings show that the bonding of the composite onto aluminium plate increased the natural frequency (stiffness) of the system and its energy absorption capability by almost 40 %. It was also found that the fibre layout of AFP composite significantly improved the central deflection of the hybrid. For instance, the deflection of cross-ply hybrids was 15% less in comparison to their counterparts with unidirectional fibrous composites. Nevertheless, under the investigated energies, the fibre layout appeared to have a marginal influence on the peak contact force. Post-mortem examination showed that at an impact energy of 150 J there was no fibre failure observed in asymmetric FMLs with unidirectional composite laminates. Conversely, the fibre failure in cross-ply hybrids occurred at 150 J. This suggests that less energy is required to induce fibre failure energy in cross-ply hybrids when compared to their unidirectional hybrid counterparts. Furthermore, it was also found that substrate treatment was successful in preventing excessive delamination, even though its influence on the peak contact force was not significant.
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