Fibre metal laminates (FMLs) are being used to manufacture many structural components in aerospace industry because of their very high strength to weight ratios, yet the exact model for estimating fatigue crack propagation in FMLs cannot be developed because of many variable parameters affecting it. In this research, tensile strength, fatigue life and fracture toughness values of 2/1 configuration carbon reinforced aluminium laminate (CARALL), aramid reinforced aluminium laminate and glass laminate aluminium reinforced epoxy specimens have been investigated. Mechanical, chemical and electrochemical surface treatments were applied to AA 1050 face sheets to improve the adhesive properties of the laminates. The specimens were prepared using vacuum assisted resin transfer moulding technique and were cut to desired shapes. Fatigue tests were conducted on centre notched specimens according to ASTM Standard E399. Real time material data and properties of adhesive were used in definition of numerical simulation model to obtain the values of stress intensity factor at different crack lengths. It was observed that CARALL shows very superior tensile and fatigue strength because of stress distribution during failure. Numerical simulation model developed in this research accurately predicts fracture toughness of aramid reinforced aluminium laminate, CARALL and glass laminate aluminium reinforced epoxy with less than 2% error. An empirical analytical model using experimental data obtained during research was developed which accurately predicts the trend of FMLs fatigue life.

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