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Review on Manufacturing of Fibre Metal Laminates and Its Characterization Techniques International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 10, October 2017, pp. 561–578, Article ID: IJMET_08_10_063 Available online at http://iaeme.com/Home/issue/IJMET?Volume=8&Issue=10 ISSN Print: 0976-6340 and ISSN Online: 0976-6359 © IAEME Publication Scopus Indexed REVIEW ON MANUFACTURING OF FIBRE METAL LAMINATES AND ITS CHARACTERIZATION TECHNIQUES K.Logesh Research scholar, Department of Mechanical Engineering, Sathyabama University, Chennai, Tamil Nadu, India V.K.Bupesh Raja Professor & Head, Department of Automobile Engineering, Sathyabama University, Chennai, Tamil Nadu, India Vipin H Nair, Sreerag K.M, Vishvesvaran K.M and M.Balaji UG Scholar, Department of Mechanical Engineering, Veltech Dr.RR & Dr.SR University, Chennai, Tamil Nadu, India ABSTRACT Fibre Metal Laminates (FML) is new class of materials which are in high demand because of its superior mechanical and metallurgical properties. Such materials can be manufactured by a variety of ways depending on size required, end application and cost affordability. However FML are susceptible to defects which are governed by factors such as type of skin and core material selected, preparation method used, post treatment and load applied. Possible defects can be overcome by following care while preparing the material as per end requirements. FML can be used for applications which demand low weight to high strength ratio such as aeronautics, automobiles, marine and structures. Keywords: Fibre Metal Laminates, Skin, Core, Preparation Method, Mechanical Properties, Post Treatment. Cite this Article: K.Logesh, V.K.Bupesh Raja, Vipin H Nair, Sreerag K.M, Vishvesvaran K.M and M.Balaji, Review on Manufacturing of Fibre Metal Laminates and its Characterization Techniques, International Journal of Mechanical Engineering and Technology 8(10), 2017, pp. 553–560. http://iaeme.com/Home/issue/IJMET?Volume=8&Issue=10 1. INTRODUCTION Advancements in the field of materials and manufacturing have brought forward new kinds of materials. Laminate materials are new class of composite materials which have been developed recently. Such materials are tailor made to be used for specific applications. The first fibre metal laminate was developed during 1967. It was found that in comparison with a http://iaeme.com/Home/journal/IJMET 561 [email protected] K.Logesh, V.K.Bupesh Raja, Vipin H Nair, Sreerag K.M, Vishvesvaran K.M and M.Balaji typical aluminium sheet, a laminate of same thickness made of fibre and aluminium had twice the fracture toughness [1]. Like a typical composite material, laminate materials are generally produced to enhance the overall properties such as low density and corrosion resistance of the fabricated components [2-3]. However the properties of such materials get shared to give benefits as well as drawback such as low fatigue resistance and high moisture absorption [4- 14]. The innumerable combination of materials that can be combined to create a composite material, makes it open ended to research and development. Such materials are used extensively in aeronautics, automobiles and structural materials [15-19]. In this paper, sandwich material, which is a type of composite material is considered and discussed. A sandwich material consists of layers of its composition arranged to replicate a sandwich, such as plywood. Fig.1. shows the morphology of typical sandwich materials. It consists of a skin which acts as the matrix, while the interlayer acts as the reinforcements. Like any composite material, the composition of the sandwich material can be selected based on the end requirement, i.e, the properties desired from the produced composite. There can be several layers between the outer skins in the sandwich material. Figure 1 A typical laminate material [20] 1.1. History of Laminate Materials The earliest known literature about the use of bonded laminate structures dates back to 1950 [21]. It was revealed that Fokker Aero-structures of Netherlands made first attempts to prevent emergence of fatigue cracks by using laminated materials. It was identified that its performance was better than monolithic structures made up of same materials. Research on Fibre metal laminates (FML) was coined by Aerospace Engineering in Delft University of Technology, Netherlands. They developed a fibre metal laminates comprising of Aramid fibres in Aluminium laminates (ARALL) [22-23]. It was commercialized during 1982 with two variations: ARALL 1 with AA7075 as the laminate and ARALL 2 with AA2024 as the laminates. Later two more types of ARALL came into existence and commercialized respectively. More research on FML brought forward Carbon reinforced Aluminium laminates (CARALL). In 1989, Glass Laminate Aluminium Reinforced Epoxy (GLARE) was developed and patented [24]. It was later commercialized in 1991 [25]. Generally E-glass fibres are used to make GLARE. 1.2. Classifications of FML Numerous research activities in FML have given rise to many different kinds of laminated materials. Figure 2 shown below reveals the classifications of FML. Based on the layup of the reinforcements a FML can be of two types: Unidirectional Hybrid Laminate (UDHL) and Cross-ply Hybrid Laminates (CPHL). Comparatively the CPHL is better in terms of impact performance and damage resistance [26]. Fig.3 shows the general layup of reinforcements and metal laminates of a sandwich material. In case of UDHL the fibres will be either oriented in 00 or 900 orientations. In the CPHL fibres will be twined similar to the form of textile fabrics. http://iaeme.com/Home/journal/IJMET 562 [email protected] Review on Manufacturing of Fibre Metal Laminates and its Characterization Techniques Based on the material used as the laminate, FML can be of the following types: Titanium based FML, Magnesium based FML and Aluminium based FML. CARALL, GLARE and ARALL are classes of Aluminium based laminates. There are four types of ARALL and six types of GLARE, each having specific properties depending upon the types of aluminium used to fabricate the same [22-23]. The materials chosen as the laminate is such that it contributes to the reduction in weight of the FML without sacrificing its superior mechanical properties such as high strength, yield strength, impact resistance, etc. Titanium has the advantage of strength to weight ratio, however it is not preferred for low applications. The mechanical properties such as impact resistance and hardness of magnesium is lower than aluminium and titanium, hence it is preferred only for applications which do not required high strength. Aluminium has some advantages like strength to weight ratio, fatigues and corrosion resistance[24-27]. Applications of aluminium metal laminates includes aero structures and automobile components [21-24][28-31]. Based on the types of reinforcements used FML are of the following types: Kevlar reinforced laminate, CARALL and GLARE. Kevlar has the benefit of extremely light weight however being costly makes its applications restricted to scientific research and government aided projects. Glass and carbon fibre has the advantages of low cost yet reliable hence highly preferred for commercial applications [22]. Based on the layup of the laminates and reinforcements in FML can be of the following types: 2/1 laminate in which there will be one layer of reinforcement sandwiched between two metal laminates and 3/2 laminate in which there will be three layers of metal laminates separated by two layers of reinforcements. The fibre may be oriented in different directions between the laminates [32-34]. Figure 4 shows a 3/2 laminate. Figure 2 Classification of Fibre Metal Laminates http://iaeme.com/Home/journal/IJMET 563 [email protected] K.Logesh, V.K.Bupesh Raja, Vipin H Nair, Sreerag K.M, Vishvesvaran K.M and M.Balaji Figure 3 Layup of reinforcements and metal laminates in FML [35] Figure 4 3/2 laminate materials [36] 2. FABRICATION OF FML FML are prepared with an aim of reducing the overall weight without sacrificing the beneficial properties on a specific application [24][37]. Fabrication of FML consists of four steps: pre-treatment, preparation of prepreg, production of FML and post treatment. 2.1. Pre treatment The skin has to be pre-treated in order to enable proper bonding of the metal laminate with the reinforcements. The skin and the fibre reinforcements have to be cut to the required dimensions before carrying out the pre-treatment processes [38]. Modification of surface properties of the skin or metal laminate is carried out by mechanical abrasion and degreasing by using solvents [25][39]. The procedures for pre-treatment were explained with the following steps [40]: • Degreasing the metal laminates by immersing it in Methyl Ethyl Ketone (MEK) solution, • Cleaning with water, • Creation of micro roughness using a 400 and 200 grit abrasion papers. Any contaminants were wiped out using tissue papers, • Etching for 10 minutes at room temperature by immersing it in a 5% NaOH solution, • Rinsing with hot water, • Etching the metal laminate for 12 minutes in sulfochromic solution. (ASTM standard D2674-72, 2004) and (ASTM standard D2651-01, 2004) standards were used during the etching process, http://iaeme.com/Home/journal/IJMET 564 [email protected] Review on Manufacturing of Fibre Metal Laminates and its Characterization Techniques • Producing porous layers of pseudoboehmite aluminum oxyhydroxide (ALOOH) on the metal laminate by immersing it in hot water for one minute, • Coating the surface of the metal laminate using an organosilane adhesion promoter, γ- Glycidoxypropyltrimethoxy silane (γ-GPS), • Drying in an oven at 1000C for one hour. It was noted that the coating improved the strength and durability of the adhesive. The metal laminate used for his study was aluminium. 2.2. Preparation of the prepreg The preparation of FML is preceded by the manufacture of prepregs[25]. A single sheet of fabric reinforcement can be cut to the desired size and held in a mould [41]. The mould is the connected to resin feed and a vacuum source as shown in Fig.4.
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