New Advances and Future Possibilities in Forming Technology of Hybrid Metal–Polymer Composites Used in Aerospace Applications

Trzepieciński, Tomasz; Najm, Sherwan Mohammed; Sbayti, Manel; Belhadjsalah, Hédi; Szpunar, Marcin; Lemu, Hirpa G.

doi:10.3390/jcs5080217

Cited by 52 publications

(18 citation statements)

References 263 publications

(413 reference statements)

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“…Sandwich panels are promising composite materials, which combine advantages of the used mono-materials. For this reason, these possess improved properties that each monomaterial alone would not deliver, such as low density, high bending resistance, energy absorption, high load carrying capacity in combination with a low specific weight [1][2][3]. Separately, metal-polymer-metal multilayer composite systems (MPM) can compete with conventional sheet materials in the construction, naval, automotive and aerospace industries [4,5].…”

Section: Introductionmentioning

confidence: 99%

Laser Welding of Metal-Polymer-Metal Sandwich Panels

Murzin

Palkowski

Melnikov

et al. 2022

Metals

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In the production of metal-polymer multilayer composite parts, e.g., for automotive applications, the possibilities of thermal joining are limited due to the instability of the polymer core at elevated temperatures. Accordingly, such materials require a special approach to their welding. The three-layered metal-polymer-metal samples were made of DPK 30/50+ZE dual-phase steel as cover sheets that were electrolytic galvanized, and a polypropylene-polyethylene foil as core material, with thicknesses of 0.48/0.3/0.48 mm. The samples were welded on both sides using a 1.06 µm Nd:YAG ROFIN StarWeld Manual Performance laser. Significant improvements of the welding conditions are achieved by machining the edges of materials to be welded. The parameters of laser welding were chosen in such a way that the polymer structure remained almost unchanged. The weld thickness was about 40% of the thickness of each steel layer. It was established that within the selected laser processing parameters the melting occurred uniformly, while the polymer layer practically did not change its structure. Therefore, it can be stated that two-sided joint welding of metal-polymer-metal composite sandwich panels, without significant degradation of the polymer core layer, is feasible.

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Section: Introductionmentioning

confidence: 99%

Laser Welding of Metal-Polymer-Metal Sandwich Panels

Murzin

Palkowski

Melnikov

et al. 2022

Metals

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“…The composites essentially have two constituents, i.e., the hypo-eutectic blends of Al alloys and the reinforcements. The morphology of the carbide particles is pivotal for deciding the tensile characteristics of the composites [15,16]. The composites are exposed to heat treatment as per the T6 temper conditions, which are known to eventually increase the tensile strength of the composites [17][18][19][20].…”

Section: Introductionmentioning

confidence: 99%

“…Figure16. Contour and 3D Surface plots for variation of YS with varying wt.% of fly ash and HT temperature.…”

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confidence: 99%

Influence of Heat Treatment and Reinforcements on Tensile Characteristics of Aluminium AA 5083/Silicon Carbide/Fly Ash Composites

et al. 2021

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The effect of reinforcements and thermal exposure on the tensile properties of aluminium AA 5083–silicon carbide (SiC)–fly ash composites were studied in the present work. The specimens were fabricated with varying wt.% of fly ash and silicon carbide and subjected to T6 thermal cycle conditions to enhance the properties through “precipitation hardening”. The analyses of the microstructure and the elemental distribution were carried out using scanning electron microscopic (SEM) images and energy dispersive spectroscopy (EDS). The composite specimens thus subjected to thermal treatment exhibit uniform distribution of the reinforcements, and the energy dispersive spectrum exhibit the presence of Al, Si, Mg, O elements, along with the traces of few other elements. The effects of reinforcements and heat treatment on the tensile properties were investigated through a set of scientifically designed experimental trials. From the investigations, it is observed that the tensile and yield strength increases up to 160 °C, beyond which there is a slight reduction in the tensile and yield strength with an increase in temperature (i.e., 200 °C). Additionally, the % elongation of the composites decreases substantially with the inclusion of the reinforcements and thermal exposure, leading to an increase in stiffness and elastic modulus of the specimens. The improvement in the strength and elastic modulus of the composites is attributed to a number of factors, i.e., the diffusion mechanism, composition of the reinforcements, heat treatment temperatures, and grain refinement. Further, the optimisation studies and ANN modelling validated the experimental outcomes and provided the training models for the test data with the correlation coefficients for interpolating the results for different sets of parameters, thereby facilitating the fabrication of hybrid composite components for various automotive and aerospace applications.

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“…In SPIF, a rotating tool with a rounded tip at its end is used, and the desired shape is formed from clamped sheet metal [ 2 ]. In the literature [ 3 ], a review paper on new advances and future opportunities considered single point incremental to be one of the forming technologies of future-proof materials in aerospace applications. Furthermore, there is governmental, academic, and business interest in developing new manufacturing technologies, and there is also interest in ISF’s impact on the environment, particularly in what ways and to what extent ISF reduces energy needs [ 4 ].…”

Section: Introductionmentioning

confidence: 99%

Parametric Effects of Single Point Incremental Forming on Hardness of AA1100 Aluminium Alloy Sheets

et al. 2021

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When using a unique tool with different controlled path strategies in the absence of a punch and die, the local plastic deformation of a sheet is called Single Point Incremental Forming (SPIF). The lack of available knowledge regarding SPIF parameters and their effects on components has made the industry reluctant to embrace this technology. To make SPIF a significant industrial application and to convince the industry to use this technology, it is important to study mechanical properties and effective parameters prior to and after the forming process. Moreover, in order to produce a SPIF component with sufficient quality without defects, optimal process parameters should be selected. In this context, this paper offers insight into the effects of the forming tool diameter, coolant type, tool speed, and feed rates on the hardness of AA1100 aluminium alloy sheet material. Based on the research parameters, different regression equations were generated to calculate hardness. As opposed to the experimental approach, regression equations enable researchers to estimate hardness values relatively quickly and in a practicable way. The Relative Importance (RI) of SPIF parameters for expected hardness, determined with the partitioning weight method of an Artificial Neural Network (ANN), is also presented in the study. The analysis of the test results showed that hardness noticeably increased when tool speed increased. An increase in feed rate also led to an increase in hardness. In addition, the effects of various greases and coolant oil were studied using the same feed rates; when coolant oil was used, hardness increased, and when grease was applied, hardness decreased.

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New Advances and Future Possibilities in Forming Technology of Hybrid Metal–Polymer Composites Used in Aerospace Applications

Cited by 52 publications

References 263 publications

Laser Welding of Metal-Polymer-Metal Sandwich Panels

Laser Welding of Metal-Polymer-Metal Sandwich Panels

Influence of Heat Treatment and Reinforcements on Tensile Characteristics of Aluminium AA 5083/Silicon Carbide/Fly Ash Composites

Parametric Effects of Single Point Incremental Forming on Hardness of AA1100 Aluminium Alloy Sheets

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