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2nd International Conference on Materials Manufacturing and Design Engineering
2nd International Conference on Materials Manufacturing and Design Engineering
Characterization of Glass Laminate Aluminium Reinforced Epoxy-
Characterization of Glass Laminate Aluminium Reinforced Epoxy-
A Review
Manufacturing Engineering Society International Conference 2017, MESIC 2017, 28-30 June
A Review
2017, Vigo (Pontevedra), Spain
Niranjan A. Patilaa*, Sharad S. Mulikbb, Kiran S. Wangikarcc, Atul P. Kulkarnidd
Niranjan A. Patil *, Sharad S. Mulik , Kiran S. Wangikar , Atul P. Kulkarni
Costing models for capacity
a,b
KJ’s Educational optimization
Institutes Trinity Academy
c,d
in Industry
of Engineering,kondhwa 4.0:
saswad road, pune, India Trade-off
Vishwakarma
a,b
KJ’s Educational Institue
Institutes of Information
Trinity Academy of Technology, kondhwa(Bk),
Engineering,kondhwa pune,
saswad India
road, pune, India
betweenVishwakarma
used Institue
capacity
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and
of Information operational
Technology, efficiency
kondhwa(Bk), pune, India

Abstract A. Santanaa, P. Afonsoa,*, A. Zaninb, R. Wernkeb

Abstract a
University of Minho, 4800-058 Guimarães, Portugal
Due to present need of light weight andbUnochapecó, high performance structure, new hybrid materials are developed known as
89809-000 Chapecó, SC, Brazil
Due
fiber to present
metal need of(FML).
laminates light weight and high
Fiber metal performance
laminates structure,
comprises new hybrid
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of composite and metals known
bonded as
fiber metal
together withlaminates
appropriate(FML). Fiber technique.
adhesive metal laminates comprises
Mechanical of alternate
and chemical layerstreatment
surface of composite
of 2024andaluminum
metals bonded
alloy
together
metal forwith appropriate
obtaining strong adhesive
interface technique.
bond between Mechanical
aluminum andandchemical
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layer.treatment of 2024 aluminum
Due to decreased alloy
manufacturing
metaland
cost
Abstract for obtaining
time, easestrong interface
in forming, bond between
recyclability, aluminum and
thermoplastic composite
composite arelayer. Due to
preferred in decreased
this study.manufacturing
Fiber metal
cost and time,
laminates ease in by
manufactured forming, recyclability,
press molding of one thermoplastic
surface treatedcomposite
2024 aluminumare preferred in this
alloy as core study.and
material Fiber
two metal
outer
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layers
Under of manufactured
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concept by pressthermoplastic
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test,capacity
context, fire resistant of
testthese
optimizationand
fiber metal
flexural test.laminates
These by performing
results were various
further testsusing
validated such as test, low. velocity impact test, fire resistant test and
tensilesoftware
analysis
goes beyond the traditional aim of capacity maximization, contributing also for organization’s profitability and value.
flexural test. These results were further validated using analysis software.
Indeed, lean management and continuous improvement approaches suggest capacity optimization instead of
© 2017The Authors. Published by Elsevier B.V.
maximization.
© 2018
2017The
Peer-review
© The responsibility
The Authors.
Authors.
under study
Published
Publishedof capacity
byby theoptimization
Elsevier and costing
B.V.B.V. committee
ofElsevier
scientific models
of the is an important
2nd International research on
Conference topic that deserves
Materials
Peer-review under responsibility of the scientific
contributions
Peer-review under
Manufacturing from both the
andresponsibility
Design Engineering. of the scientific committee of the 2nd International Conference on Materialsand
practical and committee of
theoretical the 2nd International
perspectives. This Conference
paper on Materials
presents and Manufacturing
discusses a mathematical
Design for
model Engineering.
Manufacturing and Design Engineering.on different costing models (ABC and TDABC). A generic model has been
capacity management based
developed and itsequence,
Keywords:staking was used tometal
fibre analyze idle capacity
laminates, and to design
GLARE, mechanical strategies towards the maximization of organization’s
properties,
value. The trade-off
Keywords:staking sequence,capacity
fibre metalmaximization vs operational
laminates, GLARE, efficiency is highlighted and it is shown that capacity
mechanical properties,
optimization might hide operational inefficiency.
©1.2017
Introduction
The Authors. Published by Elsevier B.V.
1. Introduction
Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference
In the emphasis of increasing the fuel efficiency which decreases green house gases and need of light weight
2017.
In the emphasis
materials in aircraftof increasing
industry, the fuelmaterials
composite efficiency which
were decreases
of interest green
in last house These
decades. gases composite
and need of light weight
materials offer
Keywords:
materialsCostin aircraft industry,
Models; ABC; TDABC; composite materials were
Capacity Management; of interest
Idle Capacity; in lastEfficiency
Operational decades. These composite materials offer

1. Introduction
* Corresponding author. Tel.: +91-8888831470 and 8625813727.
E-mail
* The address:
Corresponding
cost patil.niranjan1393@gmail.com
author.
of idle Tel.: +91-8888831470
capacity is a fundamentalandand wangikarkirans@gmail.com
8625813727.
information for companies and their management of extreme importance
E-mail address: patil.niranjan1393@gmail.com and wangikarkirans@gmail.com
in modern production systems. In general, it is defined as unused capacity or production potential and can be measured
2351-9789© 2017 The Authors. Published by Elsevier B.V.
in several ways:
Peer-review under
tons of production,
responsibility
available
of thebyscientific
hours of manufacturing, etc. The management of the idle capacity
committee of the 2nd International Conference on Materials Manufacturing and
2351-9789© 2017 The Authors. Published Elsevier B.V.
* Paulo Afonso. Tel.:
Design Engineering.
Peer-review +351 253 510 761; fax: +351 253 604
under responsibility of the scientific committee 741 of the 2nd International Conference on Materials Manufacturing and
E-mail address:
Design Engineering.psafonso@dps.uminho.pt

2351-9789 © 2017 The Authors. Published by Elsevier B.V.

Peer-review
2351-9789 © under
2018responsibility
The Authors. of the scientificbycommittee
Published Elsevier of the Manufacturing Engineering Society International Conference 2017.
B.V.
Peer-review under responsibility of the scientific committee of the 2nd International Conference on Materials Manufacturing and
Design Engineering.
10.1016/j.promfg.2018.02.083
 Niranjan A. Patil et al. / Procedia Manufacturing 20 (2018) 554–562 555
2 Author name / Procedia Manufacturing 00 (2017) 000–000

high strength, stiffness to weight ratio, corrosion resistant, high fatigue strength as compared to metals but lacked in
impact resistant, residual stress and moisture sensitivity. To overcome disadvantages of both metals and composite,
an idea of combining both the materials in laminates also called as hybrid composites was born. Fibre metal
laminates (FML) consists of alternate metal and fibre reinforced plastic layers adhesively bonded together were
initially developed in Delft University of Technology. Commercially available FML’s are ARALL, GLARE,
CARALL and found in the same hierarchy but still GLARE is most widely used. As excellent mechanical properties
of both the constituents were achieved in FML, thus now-a-days they have a increasing amount of interest.
These fibre metal laminates have superior fatigue strength, impact resistance which is the main reason for metal
failures. These FML’s have better strength when compared to advanced aluminium alloys such as lithium
aluminium which is currently used in aircraft. All the FML’s mentioned above consist of aluminium metal which is
lighter as compared to other metals. Firstly ARALL was discovered in which aramid fibres prepeg are used with
aluminium sheet metal. Further development lead to invention of GLARE which consists of glass fibre prepeg
which gave better results than ARALL, thus it is most widely used fibre metal laminate. CARALL was developed in
recent years which used carbon fibres and gave excellent results in all test, but due to problems of metallic reaction
with carbon fibre gave instability to the material. Thus GLARE is the best option with better properties as compared
to other fibre metal laminates.

2. Literature Review

Tamer sinmazcelik et al. [1] have studied historical development, advantages and application of FML's.Fibre metal
laminates such as ARALL, GLARE, CARALL production involves five major activities :(1) surface treatments of
metallic surface. (2) Material deposition (3) cure preparation (4) cure process (5) post stretching for reserving
residual stresses of FMLwhich caused by curing process. As bonding between composite laminate and metallic layer
is a key issue for overall metal-fibre laminate performance, thus an adequate surface treatment of the metallic layer
is required. In this paper the effects of surface treatments which are improved the metallic surface morphology for a
better bonding with composite laminates have been investigated. Surface treatment methods such as mechanical,
chemical, electrochemical, coupling agents and dry surface treatments are introduced and should comparable
performance to improve fibre metal laminates. To determine the mechanical properties of FML's the author has also
reviewed the test methods of bending, fatigue, tensile, low velocity and high velocity impact and blast loading tests.

Syed Ahmed et al. [2] have determined mechanical characteristics of a perforated and a plain aluminium (Al8011)
sheets in fibre metal laminates with E-Glass fibres as reinforcing material and epoxy resin as matrix material. After
caring out appropriate surface treatments on aluminium and using adhesive system a fibre metal laminate is formed
in autoclave process. Tensile test and Flexural test were conducted experimentally and analytically on ANSYS.
Results concluded that both tensile and flexural strength (experimental) are higher in plain aluminium sheet as
compared to perforated sheets, but the perforated sheets reduce the total weight by 25%. By comparing experimental
data with that derived in Finite Element Analysis software (ANSYS) these results are agreeable.

Rajkumar et al. [3] have investigated tensile and bending behaviour of aluminium hybrid fibre metal laminates by
varying the stacking sequence. Al 6061 alloy sheet, bidirectional glass fibre, carbon fibre of 600 gsm,epoxy resin
and hardener were used to fabricate FML's with various staking sequence. FML's were manufactured by press
mould curing process after proper metal surface treatments. Tensile and flexural test were carried out at different
strain rates (1mm/min, 2mm/min, 3mm/min). Results should that tensile strength increases with increase in strain
rate but flexural strength decrease with increase in strain rates. Hierarchy of both the tensile strength and flexural
strength are summarised A3C6> A3C4G2> A3C2G4> A3G6. Interlaminar shear strength were also determined by three
point bending test which concludes that this value is higher for A3C6. Thus there is good bonding strength between
Al and CFRP leads to crack arresting in flexural test while Al and GFRP bond have greater tendency for deboning
between fibre and resin matrix.

Roebroeks et al.[4] have reviewed various beneficial properties of fibre metal laminates compared to monolithic
aluminium alloys which include fatigue, fracture toughness, fire resistance, simple production etc. Metals have low
fatigue life due to fast crack propagation this is where FML's have superior property by resisting the crack
propagation already present in metal. The melting temperature of GLARE (> 1100 0C) as compared to aluminium
556 Niranjan A. Patil et al. / Procedia Manufacturing 20 (2018) 554–562
Author name / Procedia Manufacturing00 (2017) 000–000 3

(5200C) which gives us importance of FML from safety standpoint especially for large parts of the new generation
of large aircraft. The fracture toughness behaviour of GLARE during accidental damage will cause a far less critical
situation for GLARE than for monolithic aluminium alloys. For spliced laminates the number of lap joints in the
aircraft fuselage skin might be reduced by 50% and the cost saving in production seems feasible, especially if the
splicing concept is adopted.

Sunil bhat et al. [5] has manufactured Glass Reinforced Aluminium (GLARE) comprising cooled rolled thin 2014-
T6 aerospace aluminium alloy sheets and unidirectional E-glass fibre based composite prepregs. Heat treatments
were carried out to release residual stress after checking the chemical composition of the alloy by Energy dispersive
X-ray spectroscopy. To increase the surface roughness the alloy surface is scratched by abrasive paper of 240 grit.
The assembly of fibre (sequenced as 0 0-900-00) was loaded to hydraulic press which is preheated to 90 0C. Further
pressure of 10 bar was applied and temperature raised to 160 0C for 3 hrs. Observations in optical microscopy
showed fine dispersion of Cu-Al2 and Al-Si particles in aluminium and residual stresses were measured with the
help of X-ray diffraction technique. Tensile test (ASTM D3039), Flexural test(ASTM D790), Inter-laminate shear
test(ASTM D2344) were conducted and the stresses were read as 365MPa(uts), 740MPa, 40MPa respectively.

Asundi et al. [6] has suggested Fibre Metal Laminates as advanced materials for future aircraft due to their
outstanding strength to weight ratio, fatigue insensitive, corrosion resistant, fire resistance and impact resistant
properties. These properties when compared to present Al-Li alloy sheets used in aircraft are much superior.
GLARE and CARRALL have higher mechanical properties as compared to ARALL. But due to galvanic corrosion
between carbon and aluminium sheet, GLARE (also high fire resistant) is mostly preferred. These properties are
crucial in aircraft can be easily meet by GLARE. Manufacturing cost and dimensional limits of laminates can be
overcome by using spliced laminates. This spliced laminates also reduce the number of joints thus reducing failure
probability and weight.

Baumert et al. [7] evaluated tensile and fatigue properties of FML consisting of woven glass fibre reinforced epoxy
and 2024-T3 aluminium alloy manufactured by VARTM method. VARTM has the advantage of being cheaper in
manufacturing and no dimensional limits as in case of autoclave. Some specimens were prepared by perforations
(for uniform flow of resin) and tested with plain aluminium sheets. FML with thin and thick aluminium plates with
and without holes were cured for 5hrs at 125 0F followed by 6 hrs at 1650F with low injection viscosity resin. In
tensile test it was obvious that thick sheets have more strength than thin sheets. It was concluded from fatigue test
that thick metal laminates have lower fatigue life than thin ones, due to low composite volume fraction which plays
a vital role in resisting crack propagation in metals developed due to fatigue loads. The presence of hole in some
specimen serves as crack initiator due to stress concentration surrounding the hole. Thus specimen without holes has
superior fatigue life than specimens with holes.

Sugun et al. [8] provides a simple, cost effective and widely adoptable process for the manufacturing of FML’s. For
better inter-laminar bonding aluminium 2024-T6 metal surface was treated with two types of treatments viz.,
chromic acid anodising and grit blasting and their respective results were compared. An SEM photograph showed
that roughening occurred to a greater extent to grit blasted surface as compared to anodising process. Prepeg were
prepared by RTM (Resin Transfer Moulding) process in closed mould in deep freezing in -180C for 24 hours.
Mechanical properties were determined by conducting tensile test, compression test, flexural test, inter-laminar
shear test according to ASTM standards. Results showed improvement in flexural strength for grit blasted specimen
as compared to anodising process. Thus a cost reduction is carried out in three stages viz., use of grit blasting for
metal pre-treatments, in-house preparation of prepeg and cure consolidation by closed mould process(against costly
autoclave process).

Asghar et al. [9] investigated fatigue crack growth rate (FCGR) in different types of fibre metal laminates
(CARALL, ARALL, GLARE). Metal sheets of AA1050 aluminium alloy is surface treated by mechanical, chemical
and electrochemical treatments. ARALL, GLARE, CARALL were prepared by introducing fibre reinforcements of
weave Kevlar 49,weave glass and weave carbon fibres respectively in between two plates of aluminium. Fibre metal
laminates were fabricated by using epoxy resin (araldite LY 5052) and hardener (aradur 5052) through VARTM
technique and further cured for 48 hours at room temperature in vacuum. After performing tensile test it was
 Niranjan A. Patil et al. / Procedia Manufacturing 20 (2018) 554–562 557
4 Author name / Procedia Manufacturing 00 (2017) 000–000

observed that CARALL shows superior tensile strength with respect to GLARE AND ARALL due to high strength
carbon fibres. Fibre bridge the crack growth in metal and thus minimizes fatigue crack growth rate resulting in
increased fatigue life of FML’s. Again CARALL shows a least fatigue crack growth rate due to bridging effect
influenced by nature of fibres. Also CARALL exhibit highest fracture toughness value which is 46% and 23%
higher than ARALL and GLARE respectively. SEM images verify that fibre bridging effect cause crack branching
and secondary crack initiation and propagation, which further reduces crack growth rate and improves fatigue
strength.

Monika Ostapiuk et al.[10] studied the interface between composite and metal with and without surface treatments
as it has influence on the stiffness, toughness and failure behaviour of FML. Both aluminium/glass fibre and
aluminium/carbon fibre laminates of lay-up 2/1 were fabricated by using 0.5mm thick 2024-T3 aluminium alloy. R-
glass fibre epoxy and AS7-carbon fibre epoxy prepeg of 0.5mm thick were used as a core material between two
aluminium sheets. Three surface treated aluminium sheets were prepared by only degreasing, chromic acid
anodizing (CAA) and sulphuric acid anodizing (SAA) and laminates of these sheets were prepared in autoclave
system under pressure of 400 and 650 KPa for Al/G and Al/C respectively. The wetting angle that resembles the
adhesive bonding nature of surface was measured with the use of deionized water. Wetting angles of CAA and SAA
treated surface showed 76% and 60% reduction as compared to untreated surface which concludes, a good adhesive
bonding of CAA treated surface when compared with untreated surface. A microstructure using SEM (Scanning
Electron Microscope) of untreated laminates at various pressures shows presence of voids which decreases as the
pressure increases. As voids results into delamination and creates stress concentration it should be minimized by
applying high conclave pressure. Macroscopic image of untreated aluminium surface shows no connection between
metal and composite layer.

Mohammad et al.[11] have studied the effect of interfacial adhesive bonding on the impact behaviour of glass fibre
reinforced aluminium laminates. In the experiment 1050 aluminium surface which is degreased, hand abrasion for
micro roughness, etching with alkaline and sulphochromic solution is compared with the newly modified technique
which consists of all the above processes and further producing a porous pseudoboehmite aluminium axyhroxide
layer (ALOOH) followed by coating with an organosilane adhesion promoterbᴽ-glycidoxypropyltrimethoxy silane(ᴽ-
GPS). GLARE 3/2laminates with 0.3mm thick aluminium sheet and E-glass plain woven with araldite LY5052
epoxy were cured under 15KPa pressure for 24 hours at room temperature and further post cured at 100 0C for 4
hours. A low velocity impact test was carried out by varying drop height at three energy levels of 7.5J, 10J and 20J.
The ratios of central residual deflection evaluated by image processing method for surface treated and untreated
samples for energy levels of 7.5J, 10J and 20J is 1.6:1, 1.15:1 and 1.27:1. Thus the modified surface treatment
process with good adhesion bonding shown better resistance to impact and their corresponding contact forces are
about 25% higher than conventional treated surface. Specimens with conventional treated surface(weak bonding),
the impact damage area in some cases was three times larger than that of specimen with newly modified surface
treatment technique (strong bond).

Ion dinca et al. [12] have obtained some results regarding hybrid laminates aluminium-carbon fibre and aluminium
–glass fibre by performing bending strength test, tensile strength test and notch effect test. GLARE 3/2with
aluminium foil of 0.35mm thickness treated by sonic degreasing and sand blasting cleaned was laminated with E-22
glass fibre fabric using epoxy resin P401 and tetal hardener. Both glass fibre/carbon fibre aluminium laminates are
fabricated by cold compression at 35N/m2 for 1 day and followed by 7 days in an air-ageing. Both tensile test and
three point ending test concluded that aluminium-carbon fibre laminates had superior resistant (high strength)
followed by aluminium-glass fibre laminates, while the monolithic aluminium foil showed the least strength in
bending and tensile both. These tests were also conducted by replacing P401 resin with epolam resin, the results
showed that the epolam resin has good strength especially with glass fibre. Tensile test were conducted with and
without v-notch specimens and observed that a noticeable reduction in strength of monolithic aluminium foil which
was obvious while not much change in strength of both fibre metal laminates due to the fibre bridging effect.

Daisy nestler et al. [13] studied the manufacturing process of thermoplastic based fibre metal laminates which can
be efficiently produced via a continues film stacking process of a fibre foil tape unit (FFTU) and subsequently
thermo forming. Due to time consuming production technology of thermosetting epoxy based FML with average
558 Niranjan A. Patil et al. / Procedia Manufacturing 20 (2018) 554–562
Author name / Procedia Manufacturing00 (2017) 000–000 5

time 6-7 hours lead to the development of thermoplastic based FML which has a processing time of just 45 minutes
thus increasing the production by 6 times and thereby decreasing the cost of thermoplastic FML’s. The fibre foil
tape unit method was used for mass production of fibre reinforced thermoplastic prepregs. A cylinder rolls were
used to apply pressure and temperature to bond together thermoplastic film and fibres to produce carbon fibre
reinforced polyamide (CF-PA6) and glass fibre reinforced polyamide (GF-PA6). Forming of fibre metal laminates
was carried out by isochoric hot forming of 6 layers of he continues fibre reinforced polyamide in a hydraulic press.
A performed aluminium sheets were used to press together fibre reinforced polyamides to a maximum of 250 0C for
a period of 45 minutes and gradually cooled down to room temperature. A three point bending test results showed a
significant higher maximum force i.e 65% more than steel. Also the area below the curve shows that steel absorb
less torque when compared with hybrid component and also achieves a weight reduction of upto 29%. It was also
observed that despite changing the geometric dimensions of the hybrid laminates, similar properties were achieved.

Rafael Santiago et al. [14] carried out an experimental investigation of impact on thermoplastic fibre metal
laminates based on aluminium alloy and self-reinforced polypropylene (SRPP). Due to low manufacturing cost,
better strength properties and end-of-life recyclability, there has been increased demand for the thermoplastic fibre
reinforcements as compared to thermoset fibre reinforced. Various specimens were prepared by varying aluminium
thickness (0.3mm and 0.4mm). Some specimens were manufactured based on glass fibre epoxy reinforcements and
some based on polypropylene fibre. A surface treatment of chromate coating was applied on aluminium alloy grade
2024-t3 and polypropylene adhesive film (60 µm thick) were applied between aluminium and composite layers and
heated to 1350C under pressure of 6 bar. After conducting low velocity impact test it was observed that TFML
(Thermoplastic based Fibre Metal Laminates) had higher capacity for maximum energy absorbed with no material
visual damage as compared to equivalent FML. They also concluded that thinner laminates absorb less energy with
reference to thicker laminates. But FML’s offered 17% to 47% higher ballistic limit energy higher than TFML. At
low levels of deformations, it was observed that TFML’s can absorb upto 75% more impact energy compared to
conventional FML. But TFML’s exhibit poor performance under high level of deformation and also tend to fracture
due to low toughness of metal polymer interface.

Wen-Xue Wang et al. [15] introduced a new technique to overcome one of the problems of carbon fibre aluminium
laminates and developed galvanic corrosion resistance carbon fibre metal laminates. This new technique is a nano
composite coating surface treatment method consisting of sulphuric acid or chromic acid anodizing and a SiO 2 nano-
particle reinforce organic hybrid sol-gel coating process. To check the quality of the surface treatment, corrosion test
is conducted on aluminium 2024-T3 with and without surface treatments. A electro-chemistry test showed that
neither of the two individual surface treatments (anodizing and SiO2 nano coating) proved to be sufficient for the
galvanic corrosion protection, but the combination of both the surface treatments gave a best galvanic corrosion
protection CARALL is fabricated using aluminium 2024-T3 of 0.5mm thickness and CFRP prepreg in an autoclave.
Corrosion test were conducted by immersing specimens into 3% NaCl solution for 300 hours and 900 hours at room
temperature and the results showed that the composite with nano coating has superior property to resist corrosion
even after 900 hours. A 3-point and 5-point bending test were performed and thus it was evaluated that 5-point
bending test is more suitable for experimental evaluation of the interlaminar shear strength of laminates whose
interface between layers is not on mid-plane of the laminate.

Abdullah et al. [16] mentions the vitality of the adhesion quality in mechanical properties of fibre metal laminates
and thus conducts experimental investigation of self reinforced polypropylene (SRPP) and glass fibre reinforced
polypropylene (GFPP). Due to long processing cycles, low interlaminar fracture toughness and difficulties with
repair, thermoplastics has been used as a substitute for thermoset resins. Aluminium alloy (2024-T3) of 2 mm thick
used as outer layers are surface treated by sulphuric acid anodizing process to ensure proper adhesion to composite
sheets. Two specimens were fabricated one by arranging one ply of SRPP and 8 plies of GFPP in between
aluminium sheets and the other by arranging 8 plies of GFPP in between aluminium sheets using Gluco and Xiro as
interlayer materials. Single cantilever beam (SCB) test results showed that the maximum load of SRPP system is
nearly 25% greater than GFPP system. Furthermore, after continuing the loading the crack propagation occurred in a
stable manner in SRPP, in contrast to unstable behaviour of GFPP. Due to superior adhesion property of SRPP, the
force is transferred to fibres and thus a fibre bridging effect was been observed thus increasing interfacial toughness
by 60% as compared to GFPP. Interfacial fracture energies were measured for Gluco and Xiro treated aluminium
 Niranjan A. Patil et al. / Procedia Manufacturing 20 (2018) 554–562 559
6 Author name / Procedia Manufacturing 00 (2017) 000–000

and untreated aluminium alloys which shows that Gluco treated aluminium has excellent fracture properties for both
GFPP and SRPP.

Reimund neugebauer et al. [17] have demonstrated various cutting process and forming process for fibre metal
laminates based on thermoplastic resin. A heat treated aluminium alloy (EN 6082) of thickness 0.5mm is surface
roughened and laminated with a core consisting of a carbon fibre with thermoplastic resin (polyamide 6-PA 6) of
0.075mm thickness. During CO2 laser cutting process, due to the heat affected zone the strength decreased as
compared to flexible water jet cutting and delamination was the main drawback of milling process. But the quality
of cut was higher in laser cutting compared to water jet cutting. In laser cutting there is a chance of structural
transformation of aluminium alloy at the outer most layer. By conducting V-bending test it was observed that
forming temperature affects the spring back angle. The specimen breaks if the forming temperature is too low (<
1900C) and if temperature goes beyond melting temperature (> 220 0C) the polymer matrix is pressed out of
laminate. Thus a laminate can be bend in both directions i.e transverse and in the direction of fibre at an optimal
forming temperature of 2000C.

H.J.M Woerden et al. [18] have studied about the maintenance and repair techniques of GLARE structure as it is
important issue that has to be considered during design of new and advanced materials. A repair should be such that
it should fulfil the static strength and should not decrease fatigue life of component or repair. A GLARE material
which is used in real life application such as Airbus A380 is been examined in this paper. Aluminium and GLARE
materials are used as patch materials with three and four rivet row design and further fatigue loaded with maximum
stress of 85MPa for aluminium or 120MPa for GLARE for120,000 cycles. A residual strength test conducted to
observe the static behaviour observed that in both the cases the residual strength was almost same though the
maximum strength applied in fatigue test is different. Thus, the experiment concluded that after applying maximum
fatigue load almost 1.5 times (of aluminium) on GLARE, the residual strength remains equal as that of aluminium.
Due to fatigue sensitivity and stress concentration in riveted joints, bonded repairs are being preferred. As bonded
repair requires high temperature and vacuum pressure curing, some thermal residual stresses are developed which
can be tensile and compressive depending on difference in the coefficient of thermal expansion of the patch and the
skin materials. But still thermal residual stresses in GLARE are less than the ones developed in boron/epoxy
composite. Secondary bending stresses are developed in both types of joints due to shift of neutral axis which can
reduced by joining repair patches on both sides if possible. Thus, a GLARE can be repaired with conventional tools
and methods without any additional training of engineers.

R.Subbaramaiah et al. [19] carried out experimental investigation of axial crush of fibre metal laminates particularly
on GLARE top-hat structure. GLARE formed of alternative layers of 2024-alluminium and S2-glass fibre epoxy is
formed to required top hat structure by using Rubber Pad Forming(RPF) technique which is simple and faster to
produce. Experimental observations post axial crush test should that aluminium deformed by rolling and folding
which was also been predicted in the numerical model test performed on LS-DYNA. Mean crushing force which is
nothing but internal energy per unit stroke length is at least 9% higher than equivalent bare material structure.
Specific energy absorption which is nothing but energy absorbed per unit mass of crushed material is about 16%
superior than the equivalent aluminium structure. Numerical model of top hat structure was created and tested in LS-
DYNA which predicted failures modes much similar to experimental. Numerically calculated crushing force was
agreed with experimental results with a deviation less than 5% while numerical values of specific energy absorption
are less than 2% .

Gresham et al.[20] have investigated the influence of constituent material properties, blank pre-heat temperature and
blank-holder force on the drawing behaviour of metal composite sandwich structure. Fibre metal laminates(FML)
were manufactured by placing 0.5mm thick aluminium skin material (2024-O, 2024-T3, 6061-T4) and 0.9mm thick
composite core material (twintex-glass fibre reinforced polypropylener ; curv-self reinforced polypropylene prepeg)
in a pneumatic press mould which is preheated at 160 oC. Number of experiments were reduced by applying
DOE(Design Of Experiment) technique in which FML constituent materials, blank temperature
(25,60,100,120,140,1600C) and blank holder force (2,8,14 KN) are the variables. Draw forming with hydraulic ram
press and pneumatic blank holder was conducted on circular FML disc at feed rate of 20mm/s until failure occurred,
observed by a drop in force-displacement curve. Drawing behaviour of FML was concluded by observing depth at
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Author name / Procedia Manufacturing00 (2017) 000–000 7

failure, draw percentage, wrinkling and delamination. Experimental results showed that low blank holder force have
high tendency to fail by wrinkling while blank holder force fail due to tearing or fracture and decrease wrinkling.
Draw depth and draw percentage were superior in 2024 aluminium material in contrast with 2024-T3 which showed
least ability to draw. As all FML with twintex core failed due to tearing in centre and requires high forming loads to
obtain same depth than curv, thus curv core shows better drawing characteristics. Increase in preheat temperature
decrease probability of failure in composite core while increases severity of delamination and wrinkling.

Carey et al. [21] studied the forming of GLARE with low power Nd-YAG laser and effect of parameter such as lay-
up, fibre orientation, aluminium, composite thickness and thermal effect on composite material. Laser forming is
preferred over conventional process due to processing speed, geometric flexibility, economical cost and 2D-3D
forming. Laser forming is non contact process which produces thermal process(internal stress) that cause plastic
strain without melting of material also called as temperature gradient mechanism(TGM). The GLARE panels are
made in hot press and consists of 0.3mm aluminium 2024-T3 and 0.125mm E-glass fibre prepeg. As internal stress
can be generated only in metallic materials, aluminium skin will pull the remaining layers of FML, thus the bend
angle drops by 33% in FML (1:1) as compared with single aluminium layer this trend continues further. As fibre
orientation changes from 0O to 90O it was observed that bend angle goes on decreasing non-linearly. Failures were
observed due to i) overheating of matrix to separate from aluminium; ii) delamination due to variable rate of cooling
between layers; iii)delamination due to stiffness of fibre which changes due to fibre orientation; iv)material failure
due to partial melting.

Anthony sexton et al.[22] carried out an experimental investigation of formability of thermoplastic(self-reinforcing

polypropylene) based fibre metal laminates. To overcome challenges of manufacturing cost and production time,
stamp forming method was used for FML’s based on self reinforcing polypropylene composite. Fibre metal
laminates comprising of 0.6mm thick 5005-0 aluminium skin material and core of 1mm thick polypropylene
composite were kept in hydraulic press at a pressure of 1MPa and heated to 1550C. Required geometry obtained by
water jet cutting for experimental setup of stamp press with hemispherical punch of 100mm diameter. Three major
forming modes were observed i.e plain strain, uniaxial tension and biaxial stretching. Surface strains were noted for
various geometries just before failure in FML and during necking in aluminium which showed that higher major
strain in fibre metal laminates and wide range of minor strain as compared to aluminium samples. Forming limit
curve, a tool for comparing formability of different materials was obtained for both aluminium and fibre metal
laminates which concluded that fibre metal laminates have larger major strain and larger range of minor strain than
aluminium.

Paranen et al. [23] conducted experimental research on impact properties of magnesium based fibre metal laminates
as magnesium is lighter material than aluminium. As AZ31B-H24 magnesium have better static properties than
other magnesium alloys as well as aluminium 2024-T3, it was preferred for lighter, high strength fibre metal
laminates. Grit blasted magnesium sheet of 0.5mm thick were laminated with S2 glass-fibre prepeg to form
magnesium based fibre metal laminates. GLARE with thickness that matches with bending stiffness of magnesium
based fibre metal laminates were prepared for comparing the results. Drop weight impact test was conducted on both
FML’s. First crack limit-energy required for first crack in surface metal layer, second cracking limit-crack observed
in both surface metal layers and perforation limit-maximum permanent central deflection were measured. Results
showed that first and second cracking limit of magnesium based FML were low as compared to GLARE while the
perforation are nearly the same. Similarly central deflections were lower in GLARE as compared to Mg based FML.
The ultrasonic test showed that delaminated areas are larger in MgFML. Thus it concluded that MgFML is less
impact resistant compared to GLARE.

Vasumathi et al.[24] replaced aluminium metal with more lighter magnesium and high cost carbon fibre with natural
jute fibre conducted bending, axial and impact loadings. CAJRMAL (Carbon-Jute Reinforced Magnesium
Laminate) and CAJRALL (Carbon-Jute Reinforced ALuminium Laminate) were prepared with 0.19mm thick
aluminium 2024 and 0.25mm thick magnesium AZ31 with various orientation and stacking sequence in
compression moulding machine. Results showed that flexural and tensile stress in both CAJRALL and CAJRMAL
are directly proportional. Results also determined using numerical methods in ANASYS software which showed
maximum variation of 11% and 12 % for CAJRALL and CAJRMAL respectively compared to experimental results.
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3. Conclusion

Fibre metal laminates are the future materials consisting advantages of both metals and composites. Using
magnesium alloy instead of aluminium could further decrease the weight but fail to achieve impact damage resistant
of aluminium alloy. Experiments concluded that CARALL has higher mechanical properties as compared to
ARALL and GLARE. But due to galvanic corrosion and unstable interface in CARALL it leads to delamination and
low static strength, thus glass fibre in preferable than carbon fibre. As delamination is most common failure mode of
FML, it can be overcome by pre-treatment of aluminium surface. Due to recyclability, less curing time, ease of
forming thermoset resin are replaced by thermoplastic resins

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