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Cold Forming Hybrid Aluminium–Carbon Fibre-Reinforced Polymer Sheets Joined by Mechanical Interlocking

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Publicado en:Journal of Composites Science vol. 9, no. 5 (2025), p. 204
Autor principal: Latorre Núria
Otros Autores: Casellas, Daniel, Costa, Josep, Garcia-Llamas, Eduard, Pujante Jaume
Publicado:
MDPI AG
Materias:
Cold
Carbon fiber reinforced plastics
Locking
Compression tests
Compression loads
Mechanical properties
Galvanic corrosion
Adhesives
Manufacturing
Buckling
Energy consumption
Composite materials
Automotive parts
Springback
Fiber reinforced polymers
Carbon
Glass fiber reinforced plastics
Cold stamping
Lubricants & lubrication
Hybrid structures
Mechanical analysis
Automobile industry
Bond strength
Curing
Shear strength
Aluminum
Punching
Cold working
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Resumen:Forming hybrid structures into complex shapes is key to address lightweighting of automotive parts. Recently, an innovative joining technique between aluminium and Carbon Fibre-Reinforced Polymer (CFRP) based on mechanical interlocking through sheet punching has been developed. However, scaling up the solution requires the assessment of challenges, such as multi-material forming and joint integrity, after forming operations. Therefore, this work proves the feasibility of forming aluminium–CFRP prepreg panels into complex omega-shaped profiles following a conventional cold-stamping process. Forming without defects was possible even in specimens featuring mechanical joints generated through punching. The effect of the CFRP position (in the inner or the outer side of the formed profile), the number of mechanical joints, the addition of a Glass Fibre-Reinforced Polymer (GFRP) intermediate layer to prevent galvanic corrosion and adequate lubrication on necking, cracking, springback behaviour and the final geometry after curing were studied. Compression tests were performed to assess the mechanical response of the hybrid profile, and the results showed that the addition of CFRP in the aluminium omega profile changed the buckling behaviour from global bending to axial folding, increasing the maximum compression load. Additionally, the presence of mechanical interlocking joints further improved the mechanical performance and led to a more controlled failure due to buckling localization in the geometric discontinuity.
ISSN:2504-477X
DOI:10.3390/jcs9050204
Fuente:Materials Science Database