Metal-polymer Composite Materials Research Articles

Achieving green and ultra-strong bonding between metals and polymers through additive manufacturing

Lightweight metal-polymer composite materials are promising solutions for reducing pollutant emissions in the fields of automotive and aerospace etc. However, their widespread application was largely dependent on the bond strength between metal and polymer. In this work, titanium alloy-polyphenylene sulfide (PPS) composite components were formed using injection molding. To facilitate the metal-polymer bonding, cylindrical protrusions were grown on the surface titanium alloy by means of additive manufacturing, selective laser melting. The results showed that the spacing between cylindrical protrusions remarkably influence the bond strength of titanium alloy-PPS composite components. At a spacing of 600 μm, the composite components exhibited the maximum bond strength of 37.82 MPa. Moreover, the bond strength could still maintain at 10.77 MPa, even at an elevated temperature of 200 °C. After annealing treatment, the bond strength slightly decreased. The composite components formed with various types of polymers exhibited high bond strength, demonstrating good applicability.

Increasing the strength of the wing structureaircraft based on the use of metal-polymer composite material

In the modern aviation industry, the task of increasing the structural strength of the aircraft wing is being actualize. The author presents an engineering methodology for power calculation and design of composite aircraft structures based on the analysis of strength characteristics of metal and metal-polymer composite materials. The paper uses theoretical and empirical research methods, as well as the results of foreign and domestic scientific materials.

Joints of Glass Laminate Aluminium Reinforced Epoxy by splicing for the manufacture of large-sized aircraft skin panels

The schemes for joining of Glass Laminate Aluminium Reinforced Epoxy by the splicing method and the choice of the optimal scheme for the manufacture of large-sized panels are considered. The structure, mechanical and fatigue characteristics of a large-sized panel manufactured according to the optimal scheme are studied. The use of the splicing method makes it possible to reduce the weight of the structure by 10¸15 % as a result of reducing rivet joints and eliminating stress concentrators (holes), as well as increasing the reliability and damage tolerance of the aircraft. Keywords: Glass Laminate Aluminium Reinforced Epoxy, joint, splicing method, large panel, fuselage skin, fuselage, metalpolymer composite materials. org80@viam.ru, nefedovajuls@inbox.ru

Computer modeling and verification of mechanical properties of metal-polymer composite materials used in the technological process of layer-by-layer growing of parts used in the technological process of layer-by-layer growing

The article presents the results of computer modeling of the microstructure of a composite material consisting of a polyamide matrix and metal inclusions. The researched composition is one of the advanced trends in the production of materials for advanced MIM technologies. This paper describes the design of a new pressing device to produce composite rods. Computer modeling of mechanical properties of composite metal-polymer material was performed in the high-level CAD system DIGIMAT module MF. Micro-level modeling of the composite made it possible to establish the relationship between the percentage of inclusions and the upper yield strength of the material and the influence of the shape of the inclusions on the tensile strength of the designed material. The computational experiment results were verified with the results of the field experiment for the samples produced by the injection molding technology and the 3D printing technology.

Investigation of Methods for Removing Polymers of a Sample Printed with a Metal-polymer Composite Material in Additive Manufacturing

Investigation of Methods for Removing Polymers of a Sample Printed with a Metal-polymer Composite Material in Additive Manufacturing

Properties of Metal-Polymer Composite Materials with Aluminum and Magnesium Matrix

Properties of Metal-Polymer Composite Materials with Aluminum and Magnesium Matrix

МЕТОДЫ ФОРМООБРАЗОВАНИЯ МЕТАЛЛОПОЛИМЕРНЫХ КОМПОЗИЦИОННЫХ МАТЕРИАЛОВ (обзор)

Fiber-laminated metal materials – as a class of metal-polymer composite materials, in which both metals and composites are used, have shown great prospects as lightweight structural materials in the transport industry. In this regard, technologies for the production of such materials and production of parts from them are of increasing interest to researchers. The review evaluates various aspects of the current state of researches and problems associated with such materials and the technologies of their shaping, and shows the prospects for their further development.

Сопротивление хрупкому разрушению и демпфирующие свойства слоистых металлополимерных композитов

One of the topical trends in modern materials science is the development and study of new layered metal-polymer composites, which are increasingly used in aerospace engineering, automotive and transport engineering. The metal base of these composites provides a high level of strength properties and impact strength, and the polymer interlayer allows obtaining high damping properties due to its ability to dissipate the energy of elastic vibrations. Of a considerable practical interest is one of the varieties of metal-polymer composite materials based on a sandwich structure — layered steel-rubber composite characterized by pronounced viscoelastic properties, which allows them to be used as vibration damping elements in transport systems. In this work, the possibility of obtaining promising layered metal-rubber composites based on low-carbon steels (Fe-2Mn-1Si steel, IF steel), aluminum alloy Al-Mg3 and heat-and-frost-resistant rubber V-14-1NTA by hot pressing is studied. The influence of the composition and design of composites on the impact strength at temperatures of 20 and −60°C and the damping ability characteristics of materials such as the tangent of the angle of mechanical losses (tg δ), the modulus of elasticity (E') and the modulus of viscosity (E'') are determined by the method of dynamic mechanical analysis. The possibility of using layered metal-rubber composites with increased resistance to brittle fracture in the region of low climatic temperatures, as well as in structural elements of transport systems with high vibration resistance is shown.

Highly Dissipative Materials for Damage Protection against Earthquake-Induced Structural Pounding.

It is a common situation that seismic excitations may lead to collisions between adjacent civil engineering structures. This phenomenon, called earthquake-induced structural pounding, may result in serious damage or even the total collapse of the colliding structures. Filling the gap between two buildings erected close to one another by using visco-elastic materials can be considered to be one of the most effective methods to avoid seismic pounding. In this paper, a new polymer–metal composite material made of polyurethane and closed-cell aluminum foam is proposed as a pounding energy absorber for protection against earthquake hazards. The composite was created in two versions, with and without an adhesive interface. A series of experiments which reflect the conditions of seismic collision were performed: quasi-static compression, dynamic uniaxial compression and low-cycle dynamic compression with 10 loops of unloading at 10% strain. The composite material’s behavior was observed and compared with respect to uniform material specimens: polymer and metal foam. The experimental results showed that the maximum energy absorption efficiency in the case of the new material with the bonding layer was improved by 34% and 49% in quasi-static and dynamic conditions, respectively, in comparison to a sole polymer bumper. Furthermore, the newly proposed composites dissipated from 35% to 44% of the energy absorbed in the cyclic procedure, whereas the polymer specimen dissipated 25%. The capacity of the maintenance of the dissipative properties throughout the complete low-cycle loading was also satisfactory: it achieved an additional 100% to 300% of the energy dissipated in the first loading–unloading loop.

ОЦЕНКА НЕСУЩЕЙ СПОСОБНОСТИ СОСТАВНОЙ КОНСТРУКЦИИ САМОЛЕТА, СОСТОЯЩЕЙ ИЗ МЕТАЛЛОПОЛИМЕРНОГО КОМПОЗИЦИОННОГО МАТЕРИАЛА И КЛАССИЧЕСКОГО МЕТАЛЛА

The requirements for modern models of aviation equipment are constantly increasing, as a result of which it is necessary to look for new ways to solve the assigned engineering tasks through the use of new materials, new principles of manufacturing and assembly, as well as through an extraordinary approach to the design of the design of modern aircraft products. In this paper, the engineering methodology of power calculation and design of composite aircraft structures combining metal-polymer composite materials and metal materials is considered. As a composite structure under study, a fragment of an aircraft wing panel is considered, including a stringer made of a traditional structural material (metal) and a metal-polymer composite material skin attached to it. Metal- polymer composite material is a layered material consisting of metal sheets and layers of polymer composite material. Previously, in [1], the characteristics of the stress-strain state (SSS) of a single metal-polymer composite material and each layer in its package were investigated. In this paper, analytical and graphical dependences of the stress state of the elements of a composite structure on their ultimate deformations are obtained. The parameters of the composite panel of the wing, working on tension, and their effect on the stress-strain state, safety margin and load-bearing capacity are investigated. The obtained graphical dependences can be used for a preliminary assessment of the strength of an element of a composite structure at the stage of working out the design concept of an aircraft airframe assembly using a metal-polymer material.

К ВОПРОСУ О ТЕХНОЛОГИИ ПРОИЗВОДСТВА ПАНЕЛЕЙ ИЗ КОМПОЗИЦИОННЫХ МАТЕРИАЛОВ С ИСПОЛЬЗОВАНИЕМ СИАЛ

The article analyzes the most successful results of the use of metal-polymer composite materials (MPCM), reflects the advantages at the current stage of development. The analysis of the use of composite materials in the design of helicopter gliders is carried out. The use of microtubules in the manufacture of double curvature panels using MPCM is considered. Improvement of technologies in the production of structures made of MPCM. The search for optimal parameters of the technological process in the production of panels of double curvature of components based on SIAL used in the aircraft design is carried out. The optimal technological process in terms of time resources, material costs, and design weight at different levels of serial production were considered as optimization criteria in this study. Numerical modeling and optimization of workflow parameters were performed in the NASTRAN CAE system (NX). Each of the combinations of optimized process variables was determined based on numerical modeling. Analysis of the optimization results showed that the growth of parameters of the working process leads to an expansion of the area of locally optimal parameters. With optimal parameters of the working process, it is assumed that the cost of work will be reduced.

КОНЦЕПТУАЛЬНОЕ ПРОЕКТИРОВАНИЕ КОНСТРУКЦИИ КРЫЛА ИЛИ ФЮЗЕЛЯЖА МАГИСТРАЛЬНОГО САМОЛЕТА ИЗ МЕТАЛЛОПОЛИМЕРНЫХ КОМПОЗИЦИОННЫХ МАТЕРИАЛОВ

The analysis of existing aircraft structures made of metal-polymer composite materials is carried out, and a list of them with passport characteristics is compiled. The Fokker F-27 Friendship, Boeing-777 and Airbus A380, which use ARALL and GLARE materials, were selected as the aircraft under study. Formulas are determined and the distribution of normal force flows between metal and composite elements in the composition of MPCM based on aluminum sheets (aluminum-fiberglass – SIAL- 1-1, SIAL-3-1 and SIAL-1441 (9/8)) and titanium alloys (samples of titanium-carbon fiber from the patent-Example 1 and Example 3). To determine these parameters, the formulas used for a composite structure made of different materials are used. On the basis of the specification known MPCM the modified formula mixture rule for calculating the strength of new materials with a given set of orientation angles of PCM and the presence of layers of sheet metal, a comparison with standard mechanical characteristics and to show the efficiency of these formulas. Using these formulas, you can determine the strength characteristics for an arbitrary composition of the MPCM package. The features of the choice of design permissible stresses for the design of the airframe of a mainline aircraft made of metal-polymer composite material are highlighted. The concept of designing aircraft airframe elements using MPCM is considered. The results of this work will allow us to determine the rational components of the metal-polymer composite material and the structure of their distribution in the airframe design at the preliminary design stage.

Dynamic modeling of biomimetic undulatory ribbon fin underwater propulsor actuated by IPMC

Abstract In this paper, electro-mechanical dynamic modeling of a biomimetic propulsor based on undulating ribbon fin is proposed. Kinematics of the system is considered as the sinusoidal undulating motion of the ribbon fin which is guided by the actuating ionic polymer metal composite material. This is a smart material that actuates when an input voltage is applied and composed of a simple RC circuit. Elongated body theory is used to produce system dynamics considering the kinematics and also the hydrodynamic parameters like drag is undertaken as the application aspect is underwater environment. The proposed model has been used to evaluate the speed and thrust of the biomimetic system. Also, the thrust efficiency can be obtained for the different input frequencies. The proposed model may contribute to the understanding of an undulating ribbon fin inspired by IPMC for the underwater locomotion.

DEPENDENCE OF GLARE DESTRUCTION MECHANISMS ON THE ELONGATION OF SAMPLES IN TESTS TO THREE-POINT FLEXURAL

Tests on bending are one of the effective ways to experimentally determine the elasticity and shear moduli. An important task in the implementation of composite materials in aerospace structures is the development of methods for determining the physical and mechanical characteristics of materials. The paper presents of tests for three-point bending of samples of metal-polymer composite material "GLAss-REinforced" Fibre Metal Laminate (GLARE) are presented. Examined samples, consisting of 17 layers, for which apparent interlayer strength of the results of tests on three-point bending was established by the method of "short beam". It was established that for the studied samples, interlayer shear mechanisms were realized at the ratio of dimensions of length to thickness of at least 10. Localization of fracture occurs in the area of the central layer, which corresponds to the requirements of standards for conducting tests of the method of short beams. Nonetheless, such GLARE tests are always accompanied by the occurrence of significant plastic deformations associated with the presence of aluminum layers in the structure of the material. With the elongation of samples of more than 10, a fracture mechanism is realized in them, during which delamination and loss of stability of the outer layers on the compressed side of the sample occur. When the elongation of samples of less than 4 four is implemented in samples takes place, the mechanism of destruction of indentation type with large nonlinear deformations. According to the test results, the dependence of the realised fracture mechanisms on the elongation of the samples is determined.

Investigation of Metal-based Composites Vibration Properties Using Modal Analysis in Combination with Wavelet Transforms Under Imitation of Operational Loads

Abstract The present article is dedicated to the study of the vibration properties of metal-based composite materials and the application of the non-destructive testing method. The main modal parameters of the metal-based composites were investigated. For experimental determination of natural frequencies and modes of oscillations, the method of scanning laser Doppler vibrometry was used. For the numerical modal analysis, the finite element method was used. The material model was a layered composite with isotropic linearly elastic layers and metal layers. The task of identifying the material model was considered as the problem of minimising the discrepancy between the calculated natural frequencies and the experimental ones. The developed method can be recommended for the determination of parameters of material models for calculating the modal characteristics of polymer–metal sandwich sheets and metallic mono-materials composite products. Methodology for identifying models of elastic behaviour of polymer–metal composite materials, based on the results of the experimental modal analysis, is presented. Wavelet-based damage detection is also presented as an appropriate approach for the identification of integral conditions of the metal–polymer–metal composite materials. Results of wavelet transform convolutions are presented.

Long-Term Efficacy of Biodegradable Metal–Polymer Composite Stents After the First and the Second Implantations into Porcine Coronary Arteries

A biodegradable coronary stent is expected to eliminate the adverse events of an otherwise eternally implanting material after vessel remodeling. Both biocorrodible metals and biodegradable polymers have been tried as the matrix of the new-generation stent. Herein, we utilized a metal-polymer composite material to combine the advantages of the high mechanical strength of metals and the adjustable degradation rate of polymers to prepare the biodegradable stent. After coating polylactide (PLA) on the surface of iron, the degradation of iron was accelerated significantly owing to the decrease of local pH resulting from the hydrolysis of PLA, etc. We implanted the metal-polymer composite stent (MPS) into the porcine artery and examined its degradation in vivo, with the corresponding metal-based stent (MBS) as a control. Microcomputed tomography (micro-CT), coronary angiography (CA), and optical coherence tomography (OCT) were performed to observe the stents and vessels during the animal experiments. The MPS exhibited faster degradation than MBS, and the inflammatory response of MPS was acceptable 12 months after implantation. Additionally, we implanted another MPS after 1-year implantation of the first MPS to investigate the result of the MPS in the second implantation. The feasibility of the biodegradable MPS in second implantation in mammals was also confirmed.

Nanoporous metal based composites: Giving polymers strength and making metals move

One of the outstanding characteristics of electroactive polymers is their large strain response under electrical stimulus, which can be utilized for actuation applications. However, for extensive mechanical use in electro-mechanical systems, they lack the necessary strength and stiffness. To improve polymer actuator strength, the incorporation of a metal reinforcement phase has been proposed: by forming an inter-penetrating metal-polymer composite, a much stronger actuator can be created. This work focuses on nanoporous metals as the metal reinforcement: they have impressive mechanical properties, while simultaneously allowing almost unhindered ion flow due to their characteristic bi-continuous structure. To explore the effects of the metal volume fraction on the ion transport, deformation and stress response of this composite, this work investigates the chemo-electro-mechanical behaviour of a nanoporous metal-polymer composite material using finite element simulations on representative volume elements at various volume fractions.

Tunable Contact of Epidermal Electronics With Skin Based on Ionic Polymer–Metal Composite Material

Epidermal electronics mounted on the body provides the robust and noninvasive interfaces to monitor the electrophysiological signals of human body. The contact characteristic of the epidermal electronics with the skin affects the accuracy of the measured signals. In this paper, ionic polymer–metal composite is used to regulate the interface force for the consistency of the contact performance. The patterns of the ionic polymer–metal composite are designed for the flexibility and the contact characteristic of the epidermal electronics with the skin. This study provides an approach for the adjustment of the contact characteristic, which is very valuable for the longtime accurate monitoring of the epidermal electronics attached on the skin.

Studying mechanical characteristics of fiber-metal laminate based on aluminum sheets and layers of carbon fiber reinforced plastics

Results of tensile strength test of layered metal-polymer composite material on the basis of aluminum alloy sheets and layers of carbon fiber reinforced plastics were analyzed. The efficiency of complex anticorrosive protection from the influence of external factors was studied.

Novel process for preparation of metal-polymer composite membranes for hydrogen separation

In the present work, a new preparation method for metal-polymer composite materials for hydrogen separation which consist of hydride-forming intermetallic compound LaNi5 and polyethylene was developed. According to this technique, the mechanical activation of the initial powder mixtures was employed to provide good interface between the phases. A series of composite membranes with various filler concentrations was synthesized and characterized by X-ray diffraction, scanning electron microscopy and differential scanning calorimetry. The gas transport properties of the obtained materials in relation to H2, O2, N2, CO2 and CH4 were tested. The results indicate that the addition of the hydride-forming intermetallic compound to the barrier polymer leads to significantly improved selectivity with respect to hydrogen. The proposed method can be considered as a promising approach to producing of high performance composite membranes for hydrogen separation.