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Metals
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Characterization and Monitoring of Metal-CFRP-Hybrid Structures
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Characterization and Monitoring of Metal-CFRP-Hybrid Structures

A special issue of Metals (ISSN 2075-4701).

Deadline for manuscript submissions: closed (29 October 2021) | Viewed by 4565

Special Issue Editor

Prof. Dr. Hans-Georg Herrmann

E-Mail Website
Guest Editor
1. Fraunhofer IZFP Institute for Nondestructive Testing, Campus E3.1, 66123 Saarbruecken, Germany
2. Chair for lightweight systems, Saarland University, Saarbruecken, Germany
Interests: lightweight design; materials characterization; condition monitoring; nondestructive testing

Special Issue Information

Dear Colleagues,

Cost-efficient lightweight design, e.g., for automotive applications, is becoming increasingly important in light of legislative and environmental restrictions. As a consequence of recent developments in lightweight design, structures composed of different materials have become of high interest for structural applications. Combining a variety of advantageous material properties, metal–carbon fiber-reinforced polymer (CFRP) hybrid structures represent one particular class.

Furthermore, metal–CFRP hybrid structures are perfectly in line with the new intelligent lightweight design philosophy of “the right material at the right place with optimized cost, quality and sustainability”.

Future challenges for industrial applications include design guidelines, interfacial phenomena (e.g., adhesion and corrosion), cost-efficient manufacturing processes, appropriate technologies for damage inspection and condition monitoring over the complete product lifecycle, and a deeper understanding of the damage mechanisms, especially at the metal–CFRP interface.

Prof. Dr. Hans-Georg Herrmann
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • metal–CFRP structure
  • intelligent lightweight design
  • condition monitoring
  • manufacturing process
  • design guideline
  • materials characterization
  • product lifecycle

Published Papers (2 papers)

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Research

12 pages, 5351 KiB  
Article
Numerical and Non-Destructive Analysis of an Aluminum-CFRP Hybrid 3D Structure
by Leandro Soares Silva, Henrique Fernandes, Michael Schwarz, Hans-Georg Herrmann and Aldemir Cavalini
Metals 2021, 11(12), 1938; https://0-doi-org.brum.beds.ac.uk/10.3390/met11121938 - 30 Nov 2021
Viewed by 1560
Abstract
Advanced materials are widely used in many industries. They play an important role especially in the aeronautic and automotive sectors where weight reduction is required in order to reduce fuel consumption. Composite materials have a high strength to weight ratio and are applied [...] Read more.
Advanced materials are widely used in many industries. They play an important role especially in the aeronautic and automotive sectors where weight reduction is required in order to reduce fuel consumption. Composite materials have a high strength to weight ratio and are applied in airplane construction. Nevertheless, sometimes it is not viable to replace all metal parts by composite ones due to the cost factor. In this sense, hybrid structures are highly welcome. In order to ensure the safety of these hybrid components during their entire life cycle, non-destructive testing evaluation (NDT&E) methods are used and sometimes they are the only option. In this study, we use infrared thermography (IRT) to inspect an aluminum-composite hybrid structure with a 3D shape. The sample has a composite part with a small metal inlay (EN AW-6082) overmolded with a thermoplastic layer. The inlay is bended to reach the desired 3D geometry. This sample was design to be used for the connection between an A- or B-pillar and a car roof made of carbon fiber reinforced polymer (CFRP). A dual-band infrared camera is used in order to capture images in two different spectral ranges. In addition, two data processing techniques for infrared images are applied to enhance the images: principal component thermography (PCT) and partial least squares thermography (PLST). Then, a signal-to-noise ratio analysis is performed with three randomly chosen previous known defects to assess the quality of the images and detected defects. Results showed that principal component thermography has a slight advantage over partial least squares thermography in our specific experiments. Specifically, for the long-wave infrared band, PCT presented, among the defects analyzed, PCT presented a mean value 12.5% higher while the standard deviation was almost three times lower than PLST. In parallel to the non-detructive analysis, a numerical finite element model was formulated in ANSYS® to analyze the total deformations to which the metal-composite-hybrid structure is subjected during a possible use. Results obtained with the numerical model indicate that the interface region between composite and metal parts is where the highest degree of deformation occur, which indicates possible regions where defects and failures may occur in real use cases. Full article
(This article belongs to the Special Issue Characterization and Monitoring of Metal-CFRP-Hybrid Structures)
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19 pages, 12355 KiB  
Article
A Mixed Numerical-Experimental Method to Characterize Metal-Polymer Interfaces for Crash Applications
by Jonas Richter, Moritz Kuhtz, Andreas Hornig, Mohamed Harhash, Heinz Palkowski and Maik Gude
Metals 2021, 11(5), 818; https://0-doi-org.brum.beds.ac.uk/10.3390/met11050818 - 18 May 2021
Cited by 11 | Viewed by 2477
Abstract
Metallic (M) and polymer (P) materials as layered hybrid metal-polymer-metal (MPM) sandwiches offer a wide range of applications by combining the advantages of both material classes. The interfaces between the materials have a considerable impact on the resulting mechanical properties of the composite [...] Read more.
Metallic (M) and polymer (P) materials as layered hybrid metal-polymer-metal (MPM) sandwiches offer a wide range of applications by combining the advantages of both material classes. The interfaces between the materials have a considerable impact on the resulting mechanical properties of the composite and its structural performance. Besides the fact that the experimental methods to determine the properties of the single constituents are well established, the characterization of interface failure behavior between dissimilar materials is very challenging. In this study, a mixed numerical–experimental approach for the determination of the mode I energy release rate is investigated. Using the example of an interface between a steel (St) and a thermoplastic polyolefin (PP/PE), the process of specimen development, experimental parameter determination, and numerical calibration is presented. A modified design of the Double Cantilever Beam (DCB) is utilized to characterize the interlaminar properties and a tailored experimental setup is presented. For this, an inverse calibration method is used by employing numerical studies using cohesive elements and the explicit solver of LS-DYNA based on the force-displacement and crack propagation results. Full article
(This article belongs to the Special Issue Characterization and Monitoring of Metal-CFRP-Hybrid Structures)
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