Experimental optimization and static characterization of modified fiber metal laminates with integrated mechanical interlock bonding system for aerospace applications

This article presents a modified version of fiber metal laminates with integrated mechanical interlock bonding system for aerospace applications. Sheet metals of Al 2024‐T3 with surface machined infinitesimal hooks are used along with impregnated glass fiber composites to manufacture a modified version of GLAss REinforced aluminum (GLARE). Static performance of the modified GLARE is examined through tensile, in‐plane shearing, and three‐point flexural bending tests. To optimize the geometry of the machined hooks to maximize the modified GLARE static performance, we developed and tested four configurations of modified GLARE with four variants of hooks' geometry, including two hook sizes, namely, nano and micro and two hook profiles, namely, curved and straight. Experimental results show that modified GLARE with Straight Nano Hooks (SNH) outperform all samples tested including the standard GLARE (without hooks) in shear, and three‐point bending tests. Whereas, a drop of about 4.5% and 3% is observed, respectively, in the elastic modulus and tensile yield strength of modified GLARE with SNHs, compared to standard GLARE. Microscopic inspection of the four configurations of modified GLARE also illustrates that SNHs generate modified GLARE with minimal manufacturing defects. The results obtained indicate that SNH is the optimum hook geometry for the development of modified GLARE. It can be considered as an alternative surface treatment for sheet metals in Fibre‐metal laminates development process as it offers a modified version of the material with comparable static performance to those manufactured by the industrial standard methodology but at a fraction of production cost. POLYM. COMPOS., 40:1510–1525, 2019. © 2018 Society of Plastics Engineers