Search

Highlights This article proposes a 6061‐T6 Al alloy and carbon fiber hybrid composite material pre‐curing and forming integrated new process, which can significantly reduce the hybrid composite material processing time, improve the production efficiency, and provide the possibility of hybrid composite materials in automotive parts applications. The process started by placing hand‐stacked carbon fiber reinforced plastic (CFRP) composites on the surface of 6061 Al alloy sheets, followed by bonding and pre‐curing of the CFRP to the Al alloy sheets through two different sets of dies in a hydraulic press, and ultimately full curing in an aging furnace. Mechanical properties of the CFRP/Al hybrid composite material were measured by flexural tests. The results show that the flexural strength of CFRP/Al hybrid composites with different layups ([90]12, [0/45/90/−45]3, and [0]12) was increased by 159%, 93.4%, and 67.9%, respectively, compared with the single 6061 Al alloy. According to the macro‐morphological observation, [90]12 lay‐up parts have the least thinning. According to the microstructure observation, no obvious cracks or voids were found in the [90]12 lay‐up parts. Elongated cracks and void defects could be found in the [0]12 lay‐up parts. For the [0/45/90/−45]3 lay‐up parts, voids are mainly exist in ±45°layups. The results of the spring‐back analysis show that the standard deviation of the formed parts obtained from the three lay‐up methods is within 1 mm, indicating that the forming effect is good. New process improves productivity and reduces production costs The flexural strength of CFRP/Al hybrid parts is greatly improved [90]°12 lay‐up parts have the least thinning and no cracks were found The forming precision of the three lay‐up parts is good [ABSTRACT FROM AUTHOR]

A hybrid composite material was obtained by stacking carbon fiber reinforced plastic (CFRP) onto 7075‐W Al alloy sheet. Mechanical properties of the CFRP/Al hybrid composite material were measured by tensile and flexural tests. To investigate the flow of the epoxy, the thinning was measured using an optical microscope and the defects were observed by a scanning electron microscope. A finite element model was established to predict the thickness and the contact pressure distributions of the CFRP/Al hybrid composite material during the forming process. The results showed that the tensile strength (TS) of the CFRP/Al hybrid composite was increased by 10% and the fracture strain was increased by 24% compared with the single 7075 Al alloy. The flexural strength (FS) and the displacement of the loading nose were improved by 13% and 75%, respectively. According to the microstructure observation, large cracks in the epoxy could be found on the side wall of the U shape part. The results of numerical analysis indicated that the low contact pressure at side wall was the main reason for the decrease of the tensile and FS and the delamination between laminates. [ABSTRACT FROM AUTHOR]