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Metals
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Metal-CFRP-Hybrid Structures
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Metal-CFRP-Hybrid Structures

A special issue of Metals (ISSN 2075-4701).

Deadline for manuscript submissions: closed (21 December 2020) | Viewed by 20136

Special Issue Editors

Prof. Dr. Joachim Hausmann

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Guest Editor
Department Component Development, Leibniz-Insitut für Verbundwerkstoffe GmbH, 67663 Kaiserslautern, Germany
Interests: composite materials; hybrid materials; component design; mechanical testing; stress analyses; residual stresses
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Marc Siebert

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Guest Editor
PFH, Department of Technology, Hansecampus, Airbusstr. 6, 21684 Stade, Germany
Interests: composite materials and structures; joining; processing; characterization
Dr. Axel von Hehl

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Guest Editor
Leibniz Institute for Materials Engineering – IWT, University of Bremen, 28359 Bremen, Germany
Interests: alloy development for additive manufacturing; multi-material design; hybrid materials; selective laser melting; heat treatment; joining
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Kay André Weidenmann

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Guest Editor
Institute for Materials Resource Management, University of Augsburg, 86159 Augsburg, Germany
Interests: hybrid composites; processing; characterization; in situ testing

Special Issue Information

Dear Colleagues,

The conference “Hybrid Materials and Structures 2020” held online in April 2020 covers the entire spectrum of topics dealing with hybrid composites, from basic materials to design and from production to application, and thus provides the basis for an in-depth understanding of application-specific material and component behavior. The only limitation is the focus on material combinations that perform structural tasks in some way.
In this regard, the material class of CFRP–metal–hybrid structures is one material system that has been investigated in the last years. The Scientific Committee of “Hybrid Materials and Structures” has therefore decided to dedicate as Special Issue of Metals to this promising material class.

Prof. Dr. Joachim Hausmann
Prof. Dr. Marc Siebert
Dr. Axel von Hehl
Prof. Dr. Kay André Weidenmann
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • intrinsic hybrid composites
  • CFRP–metal–hybrid structures
  • characterization
  • applications
  • processing
  • design
  • simulation

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Published Papers (5 papers)

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Research

23 pages, 8870 KiB  
Article
Measurement and Analysis of Residual Stresses and Warpage in Fiber Reinforced Plastic and Hybrid Components
by Tao Wu, Steffen Tinkloh, Thomas Tröster, Wolfgang Zinn and Thomas Niendorf
Metals 2021, 11(2), 335; https://doi.org/10.3390/met11020335 - 16 Feb 2021
Cited by 13 | Viewed by 4154
Abstract
Glass/carbon fiber reinforced plastic (GFRP/CFRP) and hybrid components have attracted increasing attention in lightweight applications. However, residual stresses induced in the manufacturing process of these components can result in warpage and, eventually, negatively affect the mechanical performance of the composite structures. In the [...] Read more.
Glass/carbon fiber reinforced plastic (GFRP/CFRP) and hybrid components have attracted increasing attention in lightweight applications. However, residual stresses induced in the manufacturing process of these components can result in warpage and, eventually, negatively affect the mechanical performance of the composite structures. In the present work, GFRP, CFRP, GFRP/steel and CFRP/steel hybrid components were manufactured through the prepreg-press-technology always employing the same process parameters. The residual stresses of these components were measured through the hole drilling method (HDM), based on an adequate formalism to evaluate the residual stresses for orthotropic materials including the calculation of the calibration coefficients via finite element analysis (FEA). In FEA, the real material lay-up and mechanical properties of the samples were considered. The warpage induced by residual stresses was measured after the samples were removed from the tool. The measured residual stresses and warpage of four different types of samples were compared and results were analyzed in depth. The results obtained can be extended to other hybrid materials and even could be used for designing multi-stable laminates for application in adaptive structures. Moreover, the effects of the drilling process parameters of HDM, e.g., the drilling speed, the drilling increment and the zero-depth setting, on the resulting residual stresses of GFRP were investigated. The reliability of residual stress measurements in GFRP using HDM was validated through mechanical bending tests. The conclusions concerning the choice of optimal drilling parameters for GFRP could be directly applied for other types of samples considered in the present work. Full article
(This article belongs to the Special Issue Metal-CFRP-Hybrid Structures)
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14 pages, 6411 KiB  
Article
Additive Manufacturing of Titanium with Different Surface Structures for Adhesive Bonding and Thermal Direct Joining with Fiber-Reinforced Polyether-Ether-Ketone (PEEK) for Lightweight Design Applications
by Juliane Moritz, Philipp Götze, Tom Schiefer, Lukas Stepien, Annett Klotzbach, Jens Standfuß, Elena López, Frank Brückner and Christoph Leyens
Metals 2021, 11(2), 265; https://doi.org/10.3390/met11020265 - 4 Feb 2021
Cited by 15 | Viewed by 3736
Abstract
Hybrid joints consisting of metals and fiber-reinforced polymer composites exhibit highly desirable properties for many lightweight design applications. This study investigates the potential of additively manufactured surface structures for enhancing the bond strength of such joints in comparison to face milled and laser [...] Read more.
Hybrid joints consisting of metals and fiber-reinforced polymer composites exhibit highly desirable properties for many lightweight design applications. This study investigates the potential of additively manufactured surface structures for enhancing the bond strength of such joints in comparison to face milled and laser structured surfaces. Titanium samples with different surface structures (as-built surface, groove-, and pin-shaped structures) were manufactured via electron beam melting and joined to carbon fiber-reinforced polyether-ether-ketone (PEEK) via adhesive bonding and thermal direct joining, respectively. Bond strength was evaluated by tensile shear testing. Samples were exposed to salt spray testing for 1000 h for studying bond stability under harsh environmental conditions. The initial tensile shear strengths of the additively manufactured samples were competitive to or in some cases even exceeded the values achieved with laser surface structuring for both investigated joining methods. The most promising results were found for pin-shaped surface structures. However, the hybrid joints with additively manufactured structures tended to be more susceptible to degradation during salt spray exposure. It is concluded that additively manufactured structures can be a viable alternative to laser surface structuring for both adhesive bonding and thermal direct joining of metal-polymer hybrid joints, thus opening up new potentials in lightweight design. Full article
(This article belongs to the Special Issue Metal-CFRP-Hybrid Structures)
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17 pages, 49191 KiB  
Article
The Effect of Fiber Waviness on the Residual Stress State and Its Prediction by the Hole Drilling Method in Fiber Metal Laminates: A Global-Local Finite Element Analysis
by Steffen Tinkloh, Tao Wu, Thomas Tröster and Thomas Niendorf
Metals 2021, 11(1), 156; https://doi.org/10.3390/met11010156 - 15 Jan 2021
Cited by 2 | Viewed by 2995
Abstract
In this paper, fiber waviness, as one of the most frequently occurring defects in fiber reinforced composites, is numerically investigated with regard to the formation of residual stresses in fiber metal laminates. Furthermore, the prediction of the residual stress state in the thickness [...] Read more.
In this paper, fiber waviness, as one of the most frequently occurring defects in fiber reinforced composites, is numerically investigated with regard to the formation of residual stresses in fiber metal laminates. Furthermore, the prediction of the residual stress state in the thickness direction by means of the simulated hole drilling method is studied. To this regard, a global-local finite element analysis based on the submodel technique is presented. The submodel technique essentially consists of two governing steps: In the first step, a global model is first utilized to calculate and analyze the residual stress distribution and deformation in the intrinsically joined hybrid structure. Effective cure-dependent thermo–elastic properties predicted by a numerical homogenization procedure were used to simulate the curing-process and analyze the residual stresses state. However, the dimension of the intrinsically manufactured hybrid plate is large compared to the diameter of the drilled hole (2 mm), so that a local model is necessary, which provides only a geometric partial portion of the global model. The local model takes the global stress state into account and is subsequently used to simulate the incremental hole drilling method with a refined mesh discretization. The production-related fiber waviness is modeled by an element-wise orientation approximating a sinus function. In order to validate the global-local modeling approach, a comparison between numerical results and experimental data from literature is presented. The comparison between global residual stress state (global model) and the simulated hole drilling method (local model) is used to assess the applicability and reliability of the hole drilling method in case of fiber waviness. It is found that an in-plane fiber waviness leads to a rather low variance of residual stresses over thickness. In case of an out-of-plane fiber waviness, oscillating residual stress fields occur over the entire thickness along the fiber direction. Moreover, the current limits of the incremental hole drilling method could be pointed out by the presented investigations. It is seen that the simulated results of the incremental hole drilling method are sensitive to waviness, even if the amplitude-wavelength-ratio is small. Without further adjustment of the calibration coefficients the oscillating stress and strain fields lead, in particular fiber waviness in thickness direction, to unreliable predictions. For the experimental application it can be concluded that the specimens have to be carefully examined with regard to fiber waviness. Full article
(This article belongs to the Special Issue Metal-CFRP-Hybrid Structures)
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19 pages, 4293 KiB  
Article
Experimental and Numerical Study on the Energy Absorption of Polyurethane Foam-Filled Metal/Composite Hybrid Structures
by Shuguang Yao, Zhifang Chen, Ping Xu, Zhixiang Li and Ziliang Zhao
Metals 2021, 11(1), 118; https://doi.org/10.3390/met11010118 - 9 Jan 2021
Cited by 20 | Viewed by 3866
Abstract
Hybrid structures have the advantage of combining different types of materials at the same time. The trend of lightweight design in the transportation industry has promoted the development and application of composite materials with good crashworthiness performance. Low-density crushable foam-filled metal-composite hybrid structures [...] Read more.
Hybrid structures have the advantage of combining different types of materials at the same time. The trend of lightweight design in the transportation industry has promoted the development and application of composite materials with good crashworthiness performance. Low-density crushable foam-filled metal-composite hybrid structures have potential advantages as energy-absorbing components. This study investigated the mechanical characteristics of four different polyurethane foam-filled hybrid structures and their individual components under quasi-static axial compression. The experimental results showed foam-filled hybrid structures could change the deformation mode and improve stability during the compression process. Meanwhile, these hybrid structures could also improve energy absorption compared with their individual components. Among the different configurations, specimen C-PU-C (i.e., polyurethane foam filler between an outer CFRP tube and an inner CFRP tube) had the highest energy absorption capacity, at 5.4 kJ, and specific energy absorption, at 37.3 kJ/kg. Finally, a finite element (FE) model was established to analyze the mechanical characteristics of the hybrid structures by validating the simulation results against the experimental results. Full article
(This article belongs to the Special Issue Metal-CFRP-Hybrid Structures)
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14 pages, 6739 KiB  
Article
Mechanical Properties of Thermoplastic-Based Hybrid Laminates with Regard to Layer Structure and Metal Volume Content
by Maik Trautmann, Selim Mrzljak, Frank Walther and Guntram Wagner
Metals 2020, 10(11), 1430; https://doi.org/10.3390/met10111430 - 28 Oct 2020
Cited by 9 | Viewed by 3692
Abstract
Multi layered lightweight material compounds such as hybrid laminates are composed of different layers of materials like metals and unidirectional fibre-reinforced plastics and offer high specific strength. They can be individually tailored for applications like outer cover panels for aircraft and vehicles. Many [...] Read more.
Multi layered lightweight material compounds such as hybrid laminates are composed of different layers of materials like metals and unidirectional fibre-reinforced plastics and offer high specific strength. They can be individually tailored for applications like outer cover panels for aircraft and vehicles. Many characteristics especially layer structure, volume contents of the embedded materials as well as layer surface adhesion determine the performance of a hybrid laminate. In this study, the influence of layer structure and metal volume content are evaluated with regard to the mechanical properties of the recyclable hybrid laminate CAPAAL (carbon fibre-reinforced plastics/aluminium foil laminate), which consists of the aluminium alloy AA6082 and a graded structure of glass and carbon fibre-reinforced polyamide 6. Hybrid laminates with different ratios of the fibre-reinforced plastic and numbers of aluminium layers were manufactured by thermal pressing. The consolidation quality of in total four laminate structure variations, including 2/1 and 3/2 metal-to-fibre-reinforced plastic layer structures with fibre orientation variation, were investigated by light microscopy through cross-sections and further on computed tomography. For determination and evaluation of the mechanical properties metrologically instrumented quasi-static tensile and three-point bending tests, as well as tension-tension fatigue tests for the establishment of S-N curves were performed. The results were correlated to the microstructural observations, revealing significant influence by the consolidation quality. The layer structure proved to have a proportional impact on the increase of quasi-static tensile and flexure strength with a decrease in metal volume content. Orienting some of the fibre-reinforced plastic layers in ±45° leads to a more evenly distributed fibre alignment, which results in a higher consolidation quality and less anisotropic bending properties. Fatigue results showed a more complex behaviour where not only the metal volume content seems to determine the fatigue loading capability, but also the number of metal-fibre-reinforced plastic interfaces, hinting at the importance of stress distribution between layers and its longevity over fatigue life. Full article
(This article belongs to the Special Issue Metal-CFRP-Hybrid Structures)
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