aluminum laminates

8/2/2019 Aluminum Laminates

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O K O N K W O A N D E R S O NS A L A H A H M A D

ALUMINUM LAMINATES


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OBJECTIVES

1. Material Selection2. Material Properties3. Process


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MATERIAL

GLARE Aluminum 8090

GLARE: Glass Laminate Aluminum Reinforced Epoxy

Fiber Metal Laminate

ECOS3 blast-resistant Unit Load Device

Airbus 380


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MECHANICAL PROPERTIES

Alloy 8090: has 10% lower density and 11% higher modulus thanconventional Al 2014 and 2024

AlloyDensity

(g/cm3)Ductility

( El % )Elastic

Modulus

(GPa)

Tensile

Strength

(MPa)

Longitudinal

Klc

(MPa m1/2)

Melting

Temperature

(oC)8090 2.55 4-5 77 480 75 600-6552014 2.80 70.3 418


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CHEMICAL PROPERTIES

Corrosion resistanceto operate effectively in asaltwater environment

Aluminum forms a oxide layer to protect up to 4.5-8.5 pH.Salt water does not corrode aluminumbecause of its neutral pH. A saltwater solution can, however,be a major facilitator for galvanic or dissimilar metalcorrosion, a more complex corrosive process. (USACE)

High Alkali AttackModerate Acid Attack

Resistant


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ELECTRICAL PROPERTIES

Hysteresis curve

Glass Fiber


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PROCESSING SYSTEM

RTM (Resin Transfer Molding)

VARTM (Vacuum Assisted Resin Transfer Molding)

HVARTM (Heated Vacuum Assisted Resin Transfer

Molding) and the Autoclave process


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PROCESSING FIBER

Roving : collection of glass filaments w/ minimum twist.

Forms woven roving structure.

Stitch-bonded fabric: mechanically combining the warp (0) and weft (90) rovings.


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PROCESSING FRP

Prepare Laminate (fiber-reinforced polymer (FRP)

a) Wet FRP to prevent voidsb) Control temperature & moisture


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PROCESSING METAL

Prepare Metal Sheets

2a Methyl Ethyl Ketone (MEK) for degreasing++water break test for inspection of cleaning procedure++abrasion with 400 and 200 grit aluminum-oxide paper

2b Surface Cleaning etching in alkaline by immersion in a 5% NaOH solution2c Surface Cleaning Al sheets in sulfochromic solution2d Drying Agents aluminum sheets in a boiling water bath for 60s

to produce a porous pseudoboehmite aluminum oxyhydroxide layer (ALOOH).HEAT

Regular aluminim foil is 0.024 millimetresThese sheets are 0.4 mm after surface treatment skins to .3 +_.02


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PROCESSING COMPLETION

VARTM Process:1. Mold preparation and fabric lay-up.2. Sealing the mold and creating a vacuum.3. Resin preparation and degassing.4. Resin impregnation.

5. Cure of fabricated panels.


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PROCESSING IMPORTANT NOTES

Damage size is greater (approx. 25%) in laminates with poor interfacial adhesion.

Optimal adhesion: fully penetrates into the pores of the ALOOH layer

Poor interfacial adhesion: reduction in interlaminar shearstrength (ILSS)


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REFERENCES

Hybrid Metal Laminate (HML) Manufacturing Planning 2008/12/19, Charles Pitzer, Jenn Ming Yang, Department of Materials Science andEngineering, University of California

Ringer, S.P. and K. Hono. Microstructural evolution and age hardening in aluminum alloys: atom probe field - ion microscopy andtransmission electron microscopy studies. Materials Characterization, V. 44 (2000),101-131

J. R. Davis & Associates, ASM International Handbook Committee. Aluminum and aluminum alloys

Vinod S. Agarwala, G. M. Ugiansky. New methods for corrosion testing of aluminum alloys

Ashby, Jordan. Material Selection in Design. 2005, Harper-Printice Press.

United States Army Corps of Engineers. EM 1110-2-1614 Design of Seawalls and Bulkheads. Washington DC:USACE, 1995

Bolick, Ronnie Composite fabrication via the VARTM process, Triangle Polymer Technologies, Inc / North Carolina A&T State University: STTRN0640400400, 2009

aluminum laminates

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