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Hybrid manufacturing of a 3D-shaped fiber metal laminate
RISE Research Institutes of Sweden, Materials and Production, Polymers, Fibres and Composites.
RISE Research Institutes of Sweden, Materials and Production, Polymers, Fibres and Composites.
RISE Research Institutes of Sweden, Materials and Production, Polymers, Fibres and Composites.
RISE Research Institutes of Sweden, Materials and Production, Polymers, Fibres and Composites.ORCID iD: 0000-0003-4425-5470
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2025 (English)In: Journal of Manufacturing Processes, ISSN 1526-6125, Vol. 145, p. 85-98Article in journal (Refereed) Published
Abstract [en]

This contribution presents a methodology for designing, manufacturing, and testing of a multi-material solution demonstrator of a lower control arm for electric vehicle (EV) chassis made of a three-dimensional Fiber reinforced polymer-Metal Laminate (FML). The Integrated Computational Materials Engineering (ICME) approach includes simulation methodology for process modeling, i.e. forming and draping, and part performance with the aim to reduce the developing time and related trial and errors. The challenges, besides a limited availability of resources and material input data for numerical models, include the combination of different forming methods for Glass Fiber Reinforced Polymers (GFRP) and sheet metals (aluminum alloy) with the aim of simultaneous forming of both materials. Especially the sheet metal forming needed several improvement steps regarding heat treatment state to increase the ductility and reduce crack propagation, as well as optimization of the shape of the blanks to be formed into an asymmetric, three-dimensional geometry. Assembly includes adhesive bonding of the flat FML to the curved structure, and adapters for the testing to be performed. The quasi-static misuse testing is in good agreement to the results obtained from the simulated structural performance, with the weakest location being the adhesive bond line. An outlook on potential improvements regarding process simulation for manufacturing Fiber Metal Laminates, including necessary input data, is provided. 

Place, publisher, year, edition, pages
Elsevier Ltd , 2025. Vol. 145, p. 85-98
Keywords [en]
Automobile testing; Compaction; Die castings; Fiber reinforced metals; Glass bonding; Glass fiber reinforced plastics; Glass fibers; Aa6082; Aa6181; Compaction testing; Fiber metal laminate; Fibre Metal Laminates; Finite element analyse; Finite element analyze; Glass fiber reinforced polymer; Glassfiber reinforced polymers (GFRP); Shaped fibers; Aluminum alloys
National Category
Materials Engineering
Identifiers
URN: urn:nbn:se:ri:diva-78325DOI: 10.1016/j.jmapro.2025.04.031Scopus ID: 2-s2.0-105003125724OAI: oai:DiVA.org:ri-78325DiVA, id: diva2:2000061
Note

The research leading to these results has received funding from the European Union's Horizon 2020 innovation action program under grant agreement No 101006844 – Fatigue4Light project.

Available from: 2025-09-23 Created: 2025-09-23 Last updated: 2025-09-23Bibliographically approved

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Pettersson, JockeJuntikka, Magdalena

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