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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