Fiber Metal Research Articles

A study of abrasive water jet performance on hybrid metal fiber laminate

The hybrid metal fiber laminate (MFL) composed of Titanium, Kevlar, and Jute. The MFL was manufactured using the compression molding technique. The machining of MFL is essential for achieving the required geometric shape and size to use in various industries. This is crucial for validating its functionality in different impact protection scenarios. The study systematically explores the influence of abrasive water jet pressure (AWJP), traverse rate (TR), abrasive quantity rate (AQR), and nozzle distance (ND) on the Erosion rate (ER). Through a comprehensive experimental design, the interactions and impact of these parameters on the cutting process are examined. The objective is to optimize the abrasive water jet cutting parameters to enhance the Erosion rate while preserving the structural integrity of prepared MFL. The analysis of variance (ANOVA) exploration unveiled that AWJP stood out as the most influential parameter on ER. The AWJP, TR, AQR, and ND are direct proportional with ER.

Achieving strong interfacial bonding of CFRP and magnesium alloy by modifying magnesium alloy surface via alkaline etching with EDTA addition

The interfacial properties of fibre metal laminates are closely related to the surface microstructure of metals. Herein, a hitherto unreported honeycomb-like micro/nano-porous structure was successfully fabricated on an AZ31B Mg alloy surface by incorporation of ethylenediaminetetraacetic acid disodium (EDTA-2Na) into an alkaline solution and achieved excellent interfacial bonding property between AZ31B and carbon fibre-reinforced plastic. The addition of EDTA-2Na can promote the formation of etched pores. The growing nano-scale etched pores join together to produce micro-scale pores and ultimately lead to the formation of a micro/nano-porous structure. The 60 min etched AZ31B/carbon fibre-reinforced plastic laminate exhibits a bonding strength of 25.87 MPa, which is an increase of 350.7% compared to that of the untreated sample. The significant increase in bonding strength is mostly ascribed to composite mechanical interlocking by the micro/nano-porous structure and chemical bonding through the formation of MgCO3 and MgO1+X. In addition, the characteristics of micro-pores also affect the bonding strength.

Three-dimensional active-control hygrothermal dynamic behavior of PFMLs structure subjected to laser heat treatment with dual-ellipse distribution form

Based on three-dimensional transient thermal conduction theory, the refined plate theory and Hamilton variational principle, the constitutive equations, geometrical equations, and governing equations for fiber metal laminates with piezoelectric layer (PFMLs) under hygrothermal environment is presented. Subsequently, the Newmark method and Galerkin method are used to solve the governing equations which in terms of displacement functions. The results show that electric potential function, fiber orientation, external load as well as thickness ratio have great influence on the deflection as well as normal stress. The selection of (45°/0°) fiber orientation is more resistance to deformation and normal stress.

Characterization of Fiber Metal Laminates for the Development of Subsea Housing

Fiber Metal Laminates (FML) are hybrid composites comprising metals and Fiber Reinforced Plastics (FRP). FMLs are the most widely used in aerospace, defence and automotive sectors due to their superior qualities like light weight, tensile, compression, flexural, excellent fatigue and impact resistance. The properties like strength-to-weight ratio, susceptibility to corrosion and good heat conduction of FML make it suitable for subsea applications. Commonly, FML with a combination of aluminium (Al), titanium (Ti), stainless steel (SS) alloys and FRP are widely used for ocean applications. Compared to other FML, the SS alloy-based FML is typically used in subsea applications as it has more creep and excellent corrosion resistance. In India, under the Ocean Acoustics programme of the National Institute of Ocean Technology (NIOT), an autonomous underwater Ambient Noise Measurement System (ANMS) has been developed and deployed in the shallow waters of Indian seas for the past 12 years to study the background noise prevailing in the sea. To accommodate electronics and power packs for the measurement of ambient noise at an ocean depth of 100 m, subsea housing with stainless steel 316L (SS316L) material for a pressure rating of 1 MPa has been developed. The objective of this study is to develop the FML with SS316L and FRP for reducing the weight of the housing. Based on the literature studies and Classical Laminate Theory (CLT), the FML has been fabricated as a 0.45 m (450 mm) panel with a sequence of SS316L as outer layers and E-glass fibre and carbon as the inner layers. The total thickness of the laminates is 0.006 m (6 mm). The developed FMLs are processed with water jet cutting machines to carry out various testing such as tensile, compression and flexural, which are relevant to the characterization of FML and the experimental results are described in the paper.

Photothermal defect imaging in hybrid fiber metal laminates using the virtual wave concept

This study presents photothermal imaging results of subsurface material defects within fiber metal laminates utilizing the virtual wave concept. Therefore, we theoretically analyze the propagation of the virtual wave signal in a hybrid composite laminate via the method of images. For provoking local material damage, the hybrid composite sample is subjected to a defined impact loading. The results obtained from photothermal defect imaging, utilizing rectangular laser pulse excitation, are compared with results obtained from 3D x-ray computed tomography. To sum up, we demonstrate a fast, non-invasive, and easily interpretable reconstruction of defects within macroscopic hybrid composite laminates based on the virtual wave concept.

Experimental and Numerical Investigation of the Seismic Performance of RC Moment Resisting Frames

The rehabilitation of concrete structures has been a subject of extensive investigation, exploring various facets. One such avenue involves the incorporation of fiber additives into concrete materials. In parallel, the construction of reinforced concrete structures inevitably encounters construction errors, necessitating constant efforts from researchers to devise solutions for mitigating their impact. In the context of this research, a series of experiments was conducted involving the construction and testing of five reinforced concrete moment-resisting frames. The initial sample served as the control, while two additional samples were integrated with polypropylene and metal fibers. The subsequent two samples deliberately introduced a manufacturing error through the application of air-entraining admixture materials at the beam-to-column connection. This deliberate error aimed to assess the influence of additive fibers on frames affected by manufacturing errors. Several critical parameters were subjected to evaluation, including ultimate strength, stiffness, ductility, energy dissipation capacity, and strength reduction factor. The results of these assessments demonstrated that the utilization of additive fibers contributes to an enhanced overall performance of the frames, as inferred from the aforementioned seismic parameters. Furthermore, it was established that the incorporation of these additive fibers substantially alleviates the impact of manufacturing errors on moment-resisting reinforced concrete frames. Although a significant reduction in energy dissipation capacity was observed in samples with manufacturing errors, the other seismic parameters remained relatively unaffected. Subsequently, numerical models were generated in ABAQUS software to validate the experimental findings, and their outcomes were compared with the results derived from the physical experiments.

Effect of thermoplastic particles on the mechanical performance and damage failure of notched fibre metal laminates

This study aims to explore the open-hole tension of fibre metal laminates containing thermoplastic particles experimentally and theoretically. In this regard, a vacuum bagging infusion process has been used to manufacture glass and glass metal laminates. Further, the tensile strength and damage failure modes were predicted using the Abaqus software, finite element analysis (FEA). This prediction was performed under a tensile test for notched composite laminates. The results of experimental tests indicated that the notch sensitivity is very important in terms of fracture and failures of composites. Furthermore, the findings show that the fibre metal laminates are less notch sensitive than glass composite laminates because of enhancing the composite ductility. In total, 28% of tensile strength decrease has been achieved after having holes for glass composites while the reductions were only 22%, 15% and 13% for glass composite laminates that have one, two and three aluminium layers, respectively. This reduction also becomes 4% for glass composite laminates that have one aluminium layer and thermoplastic particles and they exhibit typical ductile damage failures compared to other laminates. Further, the findings of numerical simulation for tensile strength and damage failure modes follow experimental results both qualitatively and quantitatively for notched composite laminates under tension loading.

Quasi-static indentation responses of FMLs/2.5D woven carbon-fiber honeycomb sandwich structures under different structural parameters

Here, a new type of sandwich structure made of fiber metal laminates (FMLs) as facesheet and 2.5D woven carbon-fiber (CFRP) honeycomb as core was developed. The FMLs/CFRP honeycomb sandwich structures were subjected to quasi-static indentation tests to investigate the mechanical response with the variation of panel structure, honeycomb cell element size, honeycomb core wall thickness, and honeycomb core height. In addition to experiments, a finite element method (FEM) model was also created in ABAQUS/Explicit to analyze the damage mechanisms and failure modes of honeycomb sandwich structures under quasi-static indentation. Both the experimental and FEM simulation results revealed that the honeycomb sandwich structure underwent two different failure modes under quasi-static loading: localized damage dominated by indentation and global damage due to overall bending deformation. The combination of panel strength and honeycomb core strength determined the failure mode of the sandwich structure. Damage analysis of the honeycomb core showed that it mainly underwent fiber compression damage and matrix compression damage under quasi-static indentation. This study provides guidance to optimize the design of honeycomb sandwich structures.

Surface modification strategies of 304 austenitic stainless steel plate with different micromorphology and composition for improved mechanical interlocking and chemical bonding in metal–epoxy joints

304 austenitic stainless-steel (SS) strip-based carbon fiber metal laminates (CFMLs) have raised significant concerns, in terms of their mechanical performance. On top of that, the hybrid laminates’ interlamination performance is vital in regulating their failure patterns. Along these lines, in this work, SS strips with regulatable micromorphology and composition were obtained by using physical and chemical surface modification strategies, including polishing, acid etching, anodization, and thermal treatment. The shear strength of the treated-SS/epoxy single lap joints (two treated-SS strips bonded by the epoxy resin via hot curing process) was systematically explored, and the origins of the enhancement mechanism were attributed to the resulting surface microstructure, as well as the possible chemical reactions between the treated surface and the curing agent. The etching-anodizing-thermally treated-SS (EAT-SS)/epoxy joint exhibited the maximum shear strength (16.04 MPa) and work of fracture (5.85 kJ·m−2) due to the substantial cohesive failure pattern of the epoxy. The encouraging enhancement was mainly attributed to the synergistic effect of the micro-annular pit and the nanoporous array structure of the EAT-SS surface. These effects induced a significant mechanical interlock and a plausible chemical reaction at the interface, which led to improved bonding strength between the epoxy and treated-SS surface. Overall, in this work, it was demonstrated that the combination of the anodization and thermal treatment can effectively improve the interlamination bonding properties between the SS strip and the epoxy resin due to the combination effect of mechanical interlocking and chemical bonding.

Comparative Evaluation of Different Post and Core Systems in Maxillary Molar Endodontic Treatments: An Original Study.

Maxillary molar endodontic treatments require the right post and core system. This study tested cast metal, glass fiber with composite resin, carbon fiber with composite resin, and zirconia post and core materials. Sixty removed human maxillary teeth were randomly divided into four post and core material groups (n = 15 per group). The teeth acquired their post and core system after normal endodontic treatment. Fracture resistance, cyclic fatigue resistance, and microleakage analyses were statistically assessed. The zirconia post and core material had the highest fracture resistance (mean: 900 N), followed by carbon fiber with composite resin, cast metal, and glass fiber with composite resin. Zirconia had the highest mean cycles to failure (120,000), followed by carbon fiber with composite resin (100,000), cast metal (110,000), and glass fiber with composite resin (90,000). Zirconia had the lowest mean microleakage score (1.8), and glass fiber with composite resin, the highest (3.0). The zirconia post and core material outperformed the others in fracture resistance, cyclic fatigue resistance, and sealing. The cast metal has better fracture and cycle fatigue resistance than glass fiber with composite resin. These findings help doctors choose maxillary molar endodontic post and core materials.

Mechanical characterizations on biobased FMLs, being developed for battery boxes, before and after ageing

This paper reports the activities carried out under project FENICE (Upscaling, KAVA 9, EIT Raw Materials, www.Fenice-composites.eu, 2022-2025) about improving fire resistance of electric cars batteries, in particular through the development of Fiber Metal Laminates (FML) battery boxes. The aim of this study is to analyse the corrosion behaviour of FML based on bio-based and closed loop recyclable prepregs, in typical ageing conditions (thermal ageing, neutral and cupric acetic salt spray). FML degradation, evaluated in term of residual tensile strength after ageing, along with surface corrosion is remarkably low, and also resistance to humid environment seems satisfactory. However proper inorganic surface finishing is needed, since otherwise typical automotive tests, such as salty spray chamber ageing, cannot be passed in term of corrosion resistance requirements. The project is studying surface vitrification with sol-gel formulations, since traditional painting, based on organic polymers could ensure aluminium corrosion resistance, but would inevitably decrease fire resistance, while Cr-plating is not environmentally friendly, because of its higher carbon footprint and since it would make direct aluminium recyclability impossible, so. These advanced treatments were, up to now, not compatible with the adoption in the mass production, but things are rapidly changing, following the green transition that is currently bringing a number of small revolutions in the manufacturing sector.

Thermophysical characterization of innovative and recyclable composites, being developed and considered for battery boxes mass production

This paper describes the results of preliminary thermophysical characterization carried out on recyclable & biobased Fibre Metal Laminates (FML) for lighter, more sustainable & safer battery box production, with higher fire resistance. These FMLs are designed to be suitable for the low and medium end automotive. In particular, the specific heat and the thermal conductivity of four different types of FMLs were analysed and assessed depending on temperature. The results show increasing trends of specific heat by increasing temperatures and thermal conductivity values increasing both with temperature and the density of the samples. Further studies will be carried out both to optimise the composition of the FMLs and to provide extensive assessment of the thermal and mechanical properties of the solutions so as to guarantee high thermal and mechanical performances and durability of battery boxes for electric vehicles.

Probabilistic buckling assessment and reliability of fiber-metal laminate, composite and aluminum cylindrical panels under compression with load and fabrication uncertainties

The objective of this article is to study the buckling behavior and reliability of fiber metal laminated (FML), composite and aluminum cylindrical panels under uniaxial compression taking into account fabrication and loading uncertainties. A 3D finite element modeling with ANSYS software has been implemented for this purpose. The panels are discretized using shell elements and the eigenvalue buckling analysis is conducted for the prediction of elastic buckling. The influences of load and fabrication uncertainties on the buckling load factor are studied with probabilistic analyses and the reliability of the panels is calculated. It is found that the thickness of aluminum layers is the most significant uncertain variable for the critical buckling load factor of FML panels, whereas the fiber misalignment angle of their composite layers is insignificant. As the metal volume fraction decreases, the sensitivity of the elastic buckling load factor to variations of the axial load distribution is reduced whereas its sensitivity to variations of the thickness of composite layers is increased. Consequently, the metal volume fraction is an important design parameter for the uncertain buckling behavior of the panels.

Damage failure prediction study of carbon fiber metal laminates in hot stamping process

In addressing the difficulty of forming Fiber Metal Laminates (FMLs), a laminate composed of a 0.1 mm-thick 304 Stainless Steel Foil (SSF) and Carbon Fiber Reinforced Plastics (CFRP) as the base material is prepared using a specific process. Subsequently, forming limit diagrams are obtained through hemispherical bulge forming experiments to investigate the forming performance of FMLs laminates. The damage phenomena of various forming specimens during the thermal stamping process are analyzed. Based on different damage forms, corresponding theoretical models are established to simulate and predict the forming damage modes of FMLs through simulation. The research results indicate that the stamping formability of FMLs is influenced by the damage tolerance of the thin stainless steel foil. During the thermal stamping process, FMLs may experience delamination, fracture/crack of the thin stainless steel foil, and rupture/tearing/wrinkling of the prepreg. To address these issues, cohesive elements, GTN-M-K damage, and Hashin damage models are established, providing a reasonable simulation prediction of the stamping damage phenomena of FMLs.

Numerical and experimental validation of fiber metal laminate structure for lithium-ion battery protection subjected to high-velocity impact loading

A novel structural protection based on fiber metal laminate (FML) was developed for a lithium-ion battery module to address ground impact issues in electric vehicles (EVs). To verify the battery structural protection and for experimental validation, a new high-velocity impact test methodology was proposed. FML was selected for its high strength-to-weight ratio. The design implemented was the optimum configuration identified in a prior study. Finite element models comprising FML and lithium iron phosphate batteries were developed. The numerical simulation results, which correlated well with the experiments, enabled observation of the perforation process and failure modes of the FML. In the experiment, the safety valve of the center battery in the module experienced a compression of 3.28 mm. Despite this deformation, the FML effectively protected the lithium-ion batteries, as evidenced by the stable battery voltage during the high-velocity impact test.

GLARE deformation in low-restraint state: Tensile and bending behavior

Fiber metal laminates (FMLs) possess a better weight reduction effect than traditional metal materials due to the coupling properties of heterogeneous materials, showing promise in the areas of aviation and aerospace. At present, the research on FMLs mainly focuses on the deformation properties after curing while the mechanical properties in the low-restraint state, i.e. the laminates are temporarily not cured and are formed under lower constraint stresses, are not studied in detail. Herein, the low-restraint GLARE is taken as a research object and its deformation characteristics and failure mode are studied using uniaxial tensile, bending experiments and numerical simulation in this paper. Moreover, the influence of key parameters, such as temperature, laminate structure and span length, is investigated, as well as the tensile and bending deformation behavior of GLARE in a low-restraint state is obtained. In addition, based on experimental observations, it is found that the low-restraint GLARE produces the phenomenon of interlayer slip, and the interlaminar residual stress is much smaller than the cured laminate, whereas the deformation limit and performance are improved. This paper provides theoretical bases for the in-depth analysis of deformation properties and forming laws of low-restraint GLARE, guiding further applications of laminates.

Material design using calculation phase diagram for refractory high‐entropy ceramic matrix composites

AbstractTo achieve Si‐free refractory ceramic matrix composites exposed to an oxidizing atmosphere at approximately 2000°C, a Ti–Zr–Mo ternary alloy melt‐infiltration (MI) method was developed for the production of carbon fiber‐reinforced refractory high‐entropy ceramic matrix composites (C/RHECs), with high‐entropy carbides serving as the matrix. This approach was designed using calculation phase diagrams (CALPHADs) and the calculation of thermodynamic parameters. The combination of CALPHAD and the calculation of alloy and carbon reactivity enabled the prediction of reaction and infiltration behavior into a preform comprising carbon fiber, carbon black, and transition metal carbide powders. Furthermore, C/RHECs featuring a (Ti, Zr, Hf, Nb, Ta, Nb, Mo)C matrix were experimentally fabricated through the Ti–Zr–Mo alloy MI method in accordance with the design. The arc‐wind tunnel tests on the C/RHECs conducted at approximately 2000°C revealed surfaces covered with complex oxides. The apparent oxidation rate of the C/RHECs was similar to that of Si‐containing ceramics and composites. These results indicate that complex oxides act as a barrier to oxygen diffusion toward unoxidized regions, making Si no longer essential for protecting materials from oxidation above 2000°C.

On the energy absorption in a novel CoFeSiB metallic‐glass fiber/epoxy resin composite under quasi‐static and dynamic compression conditions

AbstractManufacturing and investigating metallic‐glass‐fiber‐reinforced epoxies is an important new attempt to present their potential to contribute to the aviation industry. In order to explore the energy absorption in novel CoFeSiB metallic‐glass‐fiber/epoxy resin composites, CoFeSiB/epoxy resin composite cylinders with different fiber volume fractions were prepared by a hot‐pressing method. The amorphism of the metal fibers was analyzed using x‐ray diffraction. The quasi‐static compression tests were performed on different fiber oriented samples with a diameter of 3.6 mm and a height of 7.2 mm. The sample with the fiber orientation [0°/90°] has a higher energy absorption capacity, compared to the one with the fiber orientation [0°/0°]. The dynamic‐ compression tests were performed on the [0°/0°] samples with a diameter of 3 mm and height of 6 mm at different air pressures. The compression fracture surfaces were examined by scanning electron microscope. Then the energy absorption mechanism of the composites was investigated. This study is of great significance for the energy absorption in amorphous metal fiber/epoxy composites.

A strategy of fabricating efficient Mg2Ni nano-catalysts in Mg-Ni-Ag fibers and their excellent hydrogen storage properties at near-room temperatures

In this study, a new strategy was utilized to fabricate Mg-based hydrogen storage fibers with uniform elemental distribution and diameters of 30–50 μm. The in-situ formation of nano-precipitates in Mg85Ni14.8Ag0.2 metallic glass fibers was visually observed at varied annealing temperatures. It indicates the metastable Mg6Ni phase is formed from an amorphous microstructure initially. Then, the needle-like Mg2Ni nanoparticles precipitate at 140–160 °C and subsequently grow into spherical shapes. This results in the formation of the fiber structure with well-distributed nano-Mg2Ni particles. The alloy fibers can absorb H2 at only 40 °C, and the activation energy for hydrogenation is lowed to be 46.9 kJ/mol. The onset desorption temperature of hydride is reduced to 220 °C due to the improved the catalytic efficiency by uniformly distributed Mg2Ni nanoparticles. The abundant interfaces, as well as the shortened distance by micropores, serve as paths for the fast diffusion of H atoms.

Modeling electromechanical behaviors of soft conductive composites embedded with liquid metal fibers

Soft conductive materials are key components of soft electronics, sensors, actuators, and wearable devices. The electrical conductivity matrix or tensor of soft conductive materials is usually deformation-dependent, but there is a lack of constitutive modeling work on it. To fill this knowledge gap, we consider a soft conductive composite embedded with liquid metal fibers as an example. The difference between the material conductivity and spatial conductivity is clarified briefly. In addition, we devise two constitutive models for the deformation-dependent conductivity tensors. These two models are equivalent but in different formats, one using stretch ratios and the other using invariants. Besides the conductivity models, a transversely isotropic hyperelastic model is also presented to model the mechanical behaviors. These analytical models are fitted and validated using data from multiphysics computational modeling on representative volume elements. Note that the proposed models can also be used for other soft conductive materials as well as thermal conductivity modeling.