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Fiber metal laminates (FML) are used in outer covering of the fuselage skin structure. The thrust force and the torque generated during drilling process affect the quality of the holes on the structure. The magnitude of cutting forces is controlled by optimizing the drilling process parameters. In this study, the influence of drilling parameters such as spindle speed, feed rate and the weight percentage of layered double hydroxides (LDH) in the binder epoxy on the thrust force and torque during drilling operation was studied. The experiments were designed based on Taguchi’s L₉ orthogonal array. The Gray Relational Analysis was used as multi-objective optimization tool for finding the optimal combination of process parameters. The spindle speed was identified as the most influencing process parameter to affect the drill quality in the FMLs. SEM images taken on the drilled specimens for the best and worst input parameter settings were compared and discussed. The regression models were generated to predict the output response values within the range of actual experiments.

The present study investigates the vibration analysis of cylindrical shells composed of fiber metal laminate (FML) with embedded piezoelectric layers, undergoing fluid-structure interaction (FSI) and resting on a Pasternak elastic foundation based on the principles of three-dimensional elasticity theory. Using the state space approach, the equations of motion were derived under simply supported boundary conditions. The natural frequencies of the FML cylindrical shell, accounting for the presence of a moving fluid, were computed by solving the eigenfrequency equations. The study examined the influence of various parameters, including boundary conditions, length-to-radius ratio, fluid type, fluid velocity, circumferential wave number, and radius-to-thickness ratio, on glass-reinforced aluminum laminate (GLARE), aramid-reinforced aluminum laminate (ARALL), and carbon-reinforced aluminum laminate (CARALL). A constant composite/metal volume ratio was assumed. The results obtained were validated by comparing with natural frequency values from the existing literature, confirming the agreement and convergence with previous studies. The results confirm that the highest natural frequency values are assigned to the CARALL, ARALL and GRALE structures in descending order. Furthermore, an increase in fluid flow velocity through the cylindrical shell correlates with a reduction in natural frequency.

Since lightweight and energy-absorbing materials have an effective role in occupant safety during accidents, the use of hybrid aluminum–composite tubes and their optimum designs are of great importance in the crashworthiness. In this study, finite element simulation and multi-objective optimization of a hybrid aluminum–composite tube are performed under axial crushing to investigate the effect of metal volume fraction (MVF) on the objective functions, the specific energy absorption and the peak force. Besides, the effects of annealing and tempering of ductile aluminum alloys (Al-6061) as the base metal of hybrid tubes are investigated. The optimum values of the objective functions are obtained at $\mathrm{\text{MVF}}\cong 0.5$ (the same thickness of aluminum and composite). Also, annealing of ductile aluminum alloys has a negative effect on the objective functions. As a guideline for the design of fiber metal laminates under crushing, it is suggested to use tempered Al-6061 and increase the thickness of composite material so that $\mathrm{\text{MVF}}<0.5$.

Thermal residual stresses (TRS) in hybrid materials and structures occur by the mismatch of thermal expansion of different materials. Especially when combining metals with carbon fiber reinforced plastics (CFRP), a significant level of internal stresses can be reached. High processing temperatures and high stiffness of the constituents are also responsible for high stress levels. Laminates of thermoplastic CFRP (unidirectional carbon fiber reinforced polyamide 6) and stainless steel foils are a suitable material system to examine the TRS in detail. Since TRSs in the steel fraction are of tensile nature, these superpose to externally applied loads, resulting in higher efforts for the material and thus reduced lifetimes under cyclic fatigue loading. Therefore, a reduction of TRS is desired. Two methods for TRS reduction were applied, and its influence on fatigue lifetime was investigated. Firstly, specimens were stretched by a preloading to reduce TRS by yielding of the metal. Secondly, non-symmetric laminates were gradually cooled down after consolidation to compensate TRS formation by non-symmetric shrinkage. While preloading of materials and structures is known for TRS modification, the gradually cooling is not established, yet. Both modification principles were numerically investigated before experimental validation. A significant increase of lifetime was reached by TRS reduction.