Simple stitch-assisted carbon fiber-aluminum laminates via out-of-autoclave process

Fiber-metal laminates (FMLs) are hybrid materials that provide the advantages of both metal and fiber-reinforced polymer composite (FRP) such as improved damage tolerance and impact strength, particularly in aerospace and automotive applications. However, the production of FMLs remains expensive because the manufacturing process is performed in an autoclave. In addition, delamination failure due to low interfacial adhesive strength between the metal and fiber layer is a problem that must be solved to improve the mechanical properties of FMLs. In this study, simple stitch-assisted carbon fiber-aluminum laminates were developed using vacuum-assisted resin transfer molding (VARTM). The FMLs produced through vacuum-assisted resin transfer molding were stitched with aramid fibers through holes on Al sheets for the resin flow associated with the VARTM. The mechanical properties of the FMLs were investigated by impact and compression after impact tests as well as double cantilever beam and flexural tests. The stitching effectively improved the interfacial strength and toughness owing to the anchoring between the aluminum and carbon fiber layers, thus preventing delamination crack propagation. As a result, the stitched FML with significantly improved interfacial adhesive and toughness was developed by the VARTM process, which will accelerate the application of FML to various lightweight structures.