Characterization and Optimization of Impact Resistance and Damage Tolerance of 3D Hybrid Composites

Abstract

This research aims to address the pressing need for environmentally sustainable lightweight materials in industries such as aerospace and automotive. This dissertation presents a comprehensive investigation into the impact resistance and damage tolerance of 3D hybrid composite materials, focusing on improving the performance of the existing rendition, three-dimensional fiber metal laminate (3DFML), and characterizing the improved material for industry adoption. The study first examines the failure mechanisms of 3DFML and compares its performance to glass fiber-reinforced aluminum laminate (GLARE) under the low-velocity impact (LVI) and compression-after-impact (CAI) conditions. A novel fabrication method is proposed, resulting in the development of Insert Enhanced 3D Hybrid Composite (IE3DHC). This new material demonstrates superior mechanical performance compared to 3DFML, with enhanced impact resistance and damage tolerance. Numerical models are developed and validated to simulate the behavior of IE3DHC under various loading conditions, providing the groundwork for future optimization. Further investigations focus on high-velocity impact (HVI) and CAI, comparing IE3DHC with traditional materials like carbon fiber-reinforced plastic (CFRP) and glass fiber-reinforced plastic (GFRP). The results show that IE3DHC outperforms these materials in post-impact residual load capacity, making it a promising candidate for lightweight structural applications. Finally, numerical models consider realistic loading conditions in the aerospace industry inspired by airworthiness standards. Design guidelines are established to estimate the impact resistance and residual load capacity of an IE3DHC panel. This research contributes to the advancement of composite materials by introducing innovative materials and fabrication methods. The developed materials show potential for use in aerospace and other industries, offering a sustainable solution to the challenges of lightweight design and environmental impact.