Evaluation of adhesion of continuous fiber–epoxy composite/aluminum laminates

Continuous fiber composite/metal laminates (FMLs) offer significant improvements over currently available composite materials for aircraft structures due to their excellent fatigue endurance and low density. Glass fiber–epoxy composite laminae and aluminum foil (GLARE) are commonly used to obtain these hybrid laminates. In this work, FMLs were produced by treating the aluminum foil to promote adhesion bonding by two methods: sulphuric chromic acid etching (SCAE) and chromic acid anodization (CAA). The surface treatments were evaluated by contact angle, roughness and scanning electron microscopy techniques. In order to compare different families of fiber composite/metal laminates, carbon fiber and glass fiber fabrics were used as reinforcements for the hybrid laminates. The adhesion of the hybrid laminates was evaluated by scanning electron microscopy (SEM) and three-point bending test. CAA resulted in better wetting properties. The interlaminar shear strength results for both carbon fiber-epoxy/metal and glass fiber-epoxy metal, were close to the interlaminar shear strength results found in the literature (approx. 40.0 MPa).     

The influence of different circular hole perforations on interlaminar shear strength of a novel fiber metal laminates

This study characterizes surface treated classic type fiber metal laminates (FMLs) interlaminar shear strength (ILSS) based on a glass mat reinforced polyphenylene sulphide composite and an aluminum alloy. The effect of concentration of γ‐glycidoxypropyltrimethoxysilane surface treatment on ILSS of adhesive bonding between aluminum sheet and composite laminates has been investigated. After determining the silane concentration, novel FML material is manufactured using a compression moulding process which involves aluminum sheets with different circular hole perforations (Array type A and B) with two circular hole diameters (ϕ3 and ϕ5 mm) and two total hole area/closed area: 0.05 and 0.06) to develop mechanical interlocking between aluminum layers and composite laminates. Tensile tests are performed to investigate the effect of different circular hole perforations on ILSS properties of FMLs. Test results show that ILSS is improved with increasing the circular hole diameter and decreased with the number of holes as correlated with undrilled FMLs. Failure modes, damage initiation, and progression of FMLs with different open hole perforations are determined with optical microscope. POLYM. COMPOS., 37:963–973, 2016. © 2014 Society of Plastics Engineers     

The fracture properties of a smart fiber metal laminate

This paper investigates the interfacial, tensile, and fatigue properties of a novel smart fiber‐metal laminate (FML) based on a nickel‐titanium (Ni‐Ti) shape memory alloy and a woven glass fiber reinforced epoxy. Initial tests, using the single cantilever beam (SCB) geometry, have shown that this unique system offers high values of metal‐composite interfacial fracture toughness. Tensile tests have shown that the mechanical properties of these FMLs lie between those offered by its constituent materials and that their tensile modulus and strength can be easily predicted using a rule of mixtures approach. Tension‐tension fatigue tests have shown that the fatigue performance of notched smart FMLs is superior to that offered by the plain Ni‐Ti alloy. A subsequent optical examination of unnotched laminates tested to failure under tension‐tension fatigue loading has shown that the fracture mechanisms occurring within the Ni‐Ti FMLs are strongly dependent on the applied cyclic stress. POLYM. COMPOS., 28:534–544, 2007. © 2007 Society of Plastics Engineers     

The impact response of aluminum foam sandwich structures based on a glass fiber-reinforced polypropylene fiber-metal laminate

The fracture properties and impact response of a series of aluminum foam sandwich structures with the glass fiber–reinforced polypropylene-based fiber-metal laminate (FML) skins have been studied. Initially, the manufacturing process for producing the FML skins was optimized to obtain a strong bond between the composite plies and the aluminum layers. The degree of adhesion between the composite plies and the aluminum was characterized by conducting single cantilever beam tests. Here, it was found that the composites could be successfully bonded to the aluminum using a simple short stamping procedure. A detailed examination of the fracture surfaces indicated that crack propagation occurred within the composite ply in the fiber-metal laminates and along the composite-aluminum foam interface in the sandwich structures. The low velocity impact response of the FMLs and the sandwich structures was investigated using an instrumented drop-weight impact tower and a laser-Doppler velocimeter. The energy absorption characteristics of the sandwich structures were investigated along with the failure processes. Finally, a series of tensile tests on the damaged FMLs and thermoplastic sandwich structures showed that both systems offer promising residual load-bearing properties. Here, shear failure in the aluminum foam was observed in the sandwich structures, indicative of a strong bond between the FML skins and the aluminum core. Polym. Compos. 25:499–509, 2004. © 2004 Society of Plastics Engineers.     

Interfacial Characteristics of Sisal Fiber and Polymeric Matrices

Sisal-fiber-reinforced composites, as a class of eco-composites, have attracted much attention from materials scientists and engineers in recent years. In this article, the effects of fiber surface treatment on fiber tensile strength and fiber-matrix interface characteristics were determined by using tensile and single fiber pullout tests, respectively. The short beam shear test was also employed to evaluate the interlaminar shear strength of the composite laminates. Vinyl ester, epoxy, and high-density polyethylene (HDPE) were chosen as matrix materials. To enhance the interfacial strength, two kinds of fiber surface-treatment methods, namely, chemical bonding and oxidisation, were used. The results obtained showed that different fiber surface-treatment methods produced different effects on the tensile strength of the sisal fiber and fiber-matrix interfacial bonding characteristics. Hence, valuable information on the interface design of sisal fiber–polymer matrix composites can be obtained from this study.     

Experimental characterization of processing-performance relationships of resistance welded graphite/polyetheretherketone composite joints

A study to investigate fusion bonding (welding) of AS4 graphite/polyetheretherketone (PEEK) thermoplastic composites is presented. Processing studies are conducted for resistance welding preconsolidated AS4/PEEK laminates in both unidirectional and quasi-isotropic configurations using PEEK and polyetherimide (PEI) film at the joint interface. All bonding was done under a constant displacement process. The influence of processing time, initially applied consolidation pressure, and the rate of heat generation on weld performance is examined through lap shear and Mode I interlaminar fracture toughness testing. A rapid increase in strength with processing time that asymptotically approaches the compression molded baseline is measured. Weld times for quasi-isotropic lap shear coupons are significantly shorter than those with a unidirectional lay-up. Variation of the initially applied consolidation pressure is shown to have little influence on the lap shear strength of PEEK film welded lap joints. A discussion of the mechanisms allowing void formation during the welding process is given. Bond strength test results are correlated with ultrasonic C-scans of the weld regions.     

Applications of fiber‐metal laminates

Advanced composite materials and fiber‐metal laminates (FMLs) have the potential to offer significant improvements in weight savings and durability in airframe structures. FMLs are an advanced hybrid material system consisting of metal layers bonded with fiber‐reinforced polymer layers. This paper presents an overview of the history of fibre‐metal‐laminates, describes several common types and also discusses the results of impact durability experiments conducted at the Structures, Materials and Propulsion Laboratory of the Institute for Aerospace Research (SMPL‐IAR) of the National Research Council Canada (NRCC). An impact fixture was developed specifically for FMLs and is also described. Numerous low velocity impact tests have been carried out that demonstrate the improved impact response of FMLs over traditional composite materials. This research builds upon earlier impact testing on carbon‐fiber‐reinforced polymers conducted by NRCC and Carleton University.     

Effect of surface treatment of pitch-based carbon fiber on mechanical properties of polyethernitrile composites

The effect of surface treatment of pitch-based carbon fiber on a new engineering thermoplastic resin, polyethernitrile, was investigated. Pitch-based carbon fiber (CF) was treated in two separate oxidizing solutions. In the first method, a nitric acid solution was used as an oxidizing agent. In the second method, a hydrogen peroxide solution was used. Both methods demonstrated that each of these solutions was a satisfactory oxidizing agent for the pitch-based CF. These treated fibers were combined with polyethernitrile polymer by the powder impregnation method, and unidirectional laminates were obtained. Improvements in both interlaminar shear strength and transverse flexural strength were achieved. The laminates fabricated from the treated CF maintained the same longitudinal flexural strength as laminates from the untreated control. In addition, scanning electron micrographs of composite fracture surfaces also showed excellent bonding of the treated fiber.     

The impact resistance of fiber–metal laminates based on glass fiber reinforced polypropylene

The high velocity impact response of a range of fiber–metal laminates (FMLs) based on a woven glass fiber reinforced polypropylene and an aluminum alloy has been investigated. Tests on FMLs, based on 2024‐O and 2024‐T3 aluminum alloys, were undertaken using a nitrogen gas gun at velocities up to 150 m/s. The failure processes in the FMLs were investigated by examining the samples after impact and by sectioning a number of specimens through the point of impact. The impact response of these multilayered samples was also characterized by measuring the residual out‐of‐plane displacement of the targets after testing. Energy absorption in the FMLs occurred through gross plastic deformation, membrane stretching and tearing in the aluminum plies, as well as delamination, fiber fracture, and matrix cracking in the composite layers. In the multilayered FMLs, the permanent displacement at the perforation threshold remained roughly constant over a range of target configurations, suggesting that the aluminum layers deform almost independently through a membrane stretching mechanism during the perforation process. The impact resistances of the laminates investigated were compared by determining their specific perforation energies (s.p.e.), where it was shown that s.p.e. of several of laminates was almost three times that of the corresponding aluminum alloy. The perforation resistances of the FMLs as well as those of the plain composite were predicted using the Reid–Wen perforation model. Here good agreement was noted between the model and the experimental data for the range of laminates investigated here. POLYM. COMPOS. 27:700–708, 2006. © 2006 Society of Plastics Engineers     

A review of the research and advances in electromagnetic joining of fiber‐reinforced thermoplastic composites

The demand for polymer composites in structural and nonstructural applications has expanded rapidly due to their lightweight, high strength, and stiffness characteristics. Joining of polymer composite is not an easy task as inadequate joint strength leads to failure of a structure due to stress concentration. The following are the three basic methods available for joining of thermoplastic composites: adhesive joining, mechanical fastening, and fusion bonding. Electromagnetic joining is a class of fusion bonding where electromagnetic force is used for generation of heat. Electromagnetic joining has gained new interest among the research fraternity with the development of thermoplastic composites. This type of joining or welding technique offers many advantages over other joining techniques. This joining technique can be used for assembly as well as repairing of thermoplastic polymer‐based composites parts. The main aim of this article is to review the different electromagnetic joining methods for thermoplastic composites and present the recent developments in this area. The electromagnetic joining methods such as induction welding, microwave welding, and resistance welding have been comprehensively discussed in the context of their applicability for joining of thermoplastic polymer‐based composites. POLYM. ENG. SCI., 59:1965–1985, 2019. © 2019 Society of Plastics Engineers     

Thermoplastic bonding to metals via injection molding for macro-composite manufacture

In this work, we explore a new method of in-situ joining of polymers to metals in injection molding to allow direct bonding between thermoplastic and metal parts. Such a method can integrate several downstream steps in product manufacture, allow optimal design of products and joints, and avoid adhesive application, assembly, and associated difficlties. A variety of process parameters and their effects upon the interface tensile strengths were examined. A full factorial experiment was conducted involving four of the critical process parameters identified. The effects upon tensile strength at break of the following process parameters were studied: (1) adherend surface temperature, (2) screw linear velocity, (3) bondline thickness, and (4) pack and hold pressure. The fracture surfaces and the thermoplastic metal interfaces were analyzed. The bonds fabricated with higher adherend surface temperatures have increased mean tensile strength and less adhesive failure. This increase in mean bond tensile strength and less adhesive failure was due to increased polymer penetration of the adherend surface roughness, at the micrometer level, as shown in the analysis of the polymer-metal interface by a scanning electron microscope (SEM).     

Dual polymer bonding of thermoplastic composite structures

This paper describes a process that facilitates fusion bonding of thermoplastic composite components without the need for complex fixtures and without disrupting the fiber alignment in the component laminates. The dual polymer bonding process, Thermabond, requires that an interlayer polymer be fused to the surface of each laminate prior to bonding. The characteristics of the interlayer polymer allow for joining of the components at a temperature below the softening/melting point of the reinforced polymer in the composite laminates. This leads to significant processing advantages without significant loss in mechanical performance. Discussions of resin compatibility, the effect of process conditions on mechanical performance, and the application of the APC-2/PEI Thermabond system to various structural components are included.     

Influence of hot compaction pressure on the interfacial properties in the amorphous metallic ribbon/thermoplastic matrix composite system

The application of rapidly solidified amorphous metal ribbons as continuous reinforcements for thermoplastic composites is examined. The metallic glass alloy Fe₄₀Ni₄₀B₂₀ (at. percent), with good stiffness, strength, and magnetic properties, was selected as the ribbon alloy. The mechanical properties of the ribbons (elastic modulus and fracture strength) were determined by tensile testing under plane-stress conditions. The continuous FE₄₀Ni₄₀B₂₀ amorphous ribbons were incorporated as reinforcements into a polypropylene (thermoplastic) matrix. To evaluate the quality of the composites formed, ribbon pullout tests were performed to measure the interfacial ribbon/matrix bond strength. It was noted that increasing the hot compaction pressure during fabrication and the surface texture of the ribbons by etching significantly improved the interfacial shear strength between the ribbon and thermoplastic matrix.     

Improved Fracture Toughness of a Titanium Alloy Laminate by Controlled Diffusion Bonding

The use of laminate composites containing a weak interface to increase the fracture toughness of high strength titanium alloys has been studied. Billets were fabricated from Ti-6A1-4V sheet material using a diffusion bonding process. Six billets were fabricated, each billet having an interface with different properties. Results indicate that toughness, as measured by the precracked Charpy test, may be increased when delamination or splitting of the bond occurs.

A simple model to predict the conditions necessary for delamination has been formulated. Correlations between the model and experimental results are made. The model can account for the effect of different base metal and interface material properties and thicknesses. It is seen that a thin, low yield strength interface material with a full strength diffusion bond to a high yield strength, fairly tough base metal leads to optimum composite toughness.     

Effects of applying a combination of surface treatments on the mechanical behavior of basalt fiber metal laminates

The surface treatment of metals has a great role on the adhesion of the metals to the polymers. There are various surface treatment methods for adhesive joint applications. However, the effect of the combination of surface treatment methods on the mechanical behavior of adhesive joints has not been extensively studied. In this study, the effects of applying a combination of surface treatments on the flexural and Charpy impact behavior of fiber metal laminates (FMLs) were investigated. The surface treatments included forest product laboratory etching (FPL), sulfuric acid anodizing (SAA), sandblasting, sandblasting + FPL and sandblasting + SAA. The FMLs were made from Al2024-T3, basalt fibers and epoxy. Scanning electron microscopy (SEM) was used to study the surface morphology of the Al2024-T3 laminates and fracture surface of the samples. Furthermore, the surface roughness of the Al2024-T3 sheets after different surface treatments were evaluated using profilometry. Results showed that the adhesion of Al2024-T3 to polymeric layers was significantly affected by various surface treatments. Results of bending tests indicated that the highest bending strength and strain to failure values were respectively achieved for the SAA and sandblast treated samples. On the other hand, although there was a slight improvement in the bending strength, the application of SAA or FPL etching after sandblasting caused a negative effect on the strain to failure value of the samples. However, impact test findings showed that the combination of FPL or SAA treatments after sandblasting rendered positive effects on the low-velocity impact behavior of the FMLs.     

Improving the adhesion of thin stainless steel sheets for fibre metal laminate (FML) applications

Thin stainless steel sheets hold considerable promise for improving several properties of aluminium based fibre metal laminates (FMLs). To allow incorporation of such sheets in FMLs their adhesion to epoxies used in aerospace applications should be at a high level. The present work describes the effects of chemical and mechanical pretreatments to regular and molybdenum-enriched AISI 301 steel sheets. Based on an in-depth knowledge of aluminium pretreatment for FML applications, also aluminium-coated stainless-steel sheets are investigated. Gritblasting was found to yield the best properties. The effect of coating the steel surface with aluminium was found to be promising, but the bond strength between the aluminium and the steel substrate proved insufficient for thin (0.1 mm) AISI 301 steel sheet.     

纤维金属层板铆接损伤机理与预测的研究

纤维金属层板铆接损伤是连接件、被连接件以及铆钉等多个复杂结构的耦合损伤行为。为了预测纤维金属层板铆接损伤行为,采用Johnson-Cook失效准则预测金属层损伤,采用三维Hashin损伤准则预测复合材料层损伤,采用脱层失效理论预测层间开裂,理论预测模型的合理性通过了实验验证。通过损伤预测模型分别考察层板铺层数量、铆接预紧力、铝合金分数和结构几何对纤维金属层板铆接损伤行为及铆接刚度的影响,为FMLs铆接设计提供可行性建议。结果表明:铺层数量的增加加剧了层板自由端层间脱层剥离现象,从而降低了层板铆接强度;铝合金分数的增加能够提高层板的铆接强度,但铝合金分数大于50%时铆接强度和铆接比强度反而下降;预紧力的增大能够延缓纤维和基体的萌生,并且提升铆接刚度,使得纤维金属铆接承受更大载荷;随着横宽径比W/D和纵宽径比E/D的递增,铆接极限强度有所提高,当W/D≥3或E/D≥3时,铆接强度不再明显提高。     

The morphing properties of a smart fiber metal laminate

This article investigates the activation characteristics of a novel fiber‐metal laminate (FML) based on a nickel–titanium (Ni–Ti) shape memory alloy. Initial attention focuses on manufacturing this smart FML in which a woven glass fiber reinforced epoxy material is sandwiched between two shape memory alloy (SMA) outer skins. Activation tests on cantilever beams using a hot air gun have shown that the FMLs exhibits a distinct actuation capability in which beam rotations of up to 11° were recorded. An examination of the edges of polished samples indicated that no damage was incurred by the FML during the activation process. The functionality of the FMLs was enhanced through the introduction of embedded electrical resistance wires located between the composite and metal plies. Here, the embedded electrical wires were heated by passing an electric current through them, thereby activating the SMA plies in a more effective and controllable manner. As before, significant beam tip rotations were recorded in the FMLs in a relatively short time period. Finally, polymer‐based optical fiber (POF) and fiber‐bragg grating (FBG) sensors were introduced into the FMLs in order to monitor their deflection during the activation process. The results of these tests showed that such sensing elements can be successfully employed to monitor the actuation response of these layered laminates. POLYM. COMPOS., 2008. © 2008 Society of Plastics Engineers     

Modified ethylene/α-octene co-polymer elastomer composites with sacrificial bonds crosslinking networks and their reinforced mechanical performance

The low tensile strength of ethylene/α-octene co-polymer (POE) limits its application as high-strength materials. In this study, 3-amino-1,2,4-triazole (ATA) was grafted onto maleic anhydride functionalized POE (PM) by melt reaction to obtain side chains capable of forming hydrogen bonding and metal coordination bonding, and then ferric chloride hexahydrate and POE are blended with them to obtain composite materials with high strength and fracture energy. The introduction of iron-based coordination bonding and hydrogen bonding double dynamic crosslinking network endow thermoplastic elastomers with excellent mechanical strength and high toughness. Fourier transform infrared spectroscopy, rheological tests, and X-ray photoelectron spectroscopy reveal the existence of non-covalent crosslinking networks. Based on the strengthening and toughening of non-covalent dynamic crosslinking network, the tensile strength of the modified POE elastomer composites achieves 12.5 MPa along with the elongation at break of 3540%. In addition, the modified POE elastomer composites exhibit improved melt elasticity and thermal stability.     

The fracture properties of a fiber metal laminate based on a self‐reinforced thermoplastic composite material

The present research program has studied the fracture properties of a Fiber‐Metal Laminate (FML) system constituted by aluminum alloy and a high‐impact self‐reinforced composite material. Here, the self‐reinforced composite system consists of a polypropylene matrix reinforced with polypropylene fibers. Initial testing has shown that a though adhesion can be achieved between the aluminum layers and the composite material by incorporating a thermoplastic adhesive interlayer at the common interface. The adhesion at the metal–composite interface has been studied under a wide range of strain rate conditions using a Single Cantilever Beam test geometry, and it has been shown that the interfacial fracture toughness is loading rate sensitive. Interlaminar delamination tests of the plain composite have also been studied and it was shown that their fracture toughness is also loading rate sensitive. Additional tensile tests have shown that the tensile strength and moduli of the FMLs are linearly influenced by the volume fraction of their constituent materials as well as are successfully predicted using a simple rule of mixture. Low velocity impact tests have also shown that the FMLs based on a self‐reinforced polypropylene composite yielded specific perforation energies well above the 30 J m²/kg. It was also shown that by increasing the number of metal and composite plies in the FMLs, resulted in hybrid structures capable of absorbing higher specific low velocity impact energies. POLYM. COMPOS., 35:427–434, 2014. © 2013 Society of Plastics Engineers