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In this article, the open‐hole tensile behaviour of carbon fibre reinforced aluminium laminates (CARALL) were investigated experimentally and numerically. Two specimens with different fibre orientations ([0°/90°/0°] and [45°/0°/−45°]), consisting of T700 carbon fibre/epoxy prepreg and 2024‐T3 aluminium with a 3/2 configuration, were manufactured by the autoclave process. Damage initiation and progression were considered in modelling the CFRP layers and interface bonding layers. Isotropic hardening behaviour was defined for aluminium layers. A major contribution of this study was to reveal the failure mechanisms and failure sequences of notched CARALL with different fibre orientations by numerical method. Damage evolution processes of the two specimens were compared. Effects of hole sizes and laminate configurations (stacking sequences & stacking structures) on both the specimens were further evaluated based on simulation. Point stress failure criterion and Wu's modified point stress failure criterion were applied in comparison with the numerical method as well. POLYM. COMPOS., 39:4123–4138, 2018. © 2017 Society of Plastics Engineers

This paper investigated the in-plane bending behaviour of carbon fibre-reinforced aluminium laminates (CARALL). The flexural progressive damage and failure mechanisms were analysed numerically and experimentally. Four types of CARALL specimens with a 3/2 configuration were prepared via hot-pressing using different aluminium alloy materials (2024-T3, 7075-T6 aluminium alloy) and fibre orientations ([0 /90 /0 ] 3 , [45 /0 /À45 ] 3 ). The three-point bending tests were conducted under static loading. It was found that the primary damage modes were aluminium layer yielding in the mid-span and delamination between the aluminium and carbon fibre-reinforced polymer (CFRP) layers. A user-defined FORTRAN subroutine VUMAT based on ABAQUS was used to simulate the failure of the CFRP, a cohesive zone model was used to predict the inter-laminar failure, and a von Mises plastic model was used to define the isotropic hardening behaviour of the aluminium layers. The predicted results agreed well with the experimental ones. Two convenient calculation methods based on the elasticity mechanics and material mechanics were derived. And the non-linear behaviour of aluminium was considered in the elasticity mechanics method. The theoretical results matched closely with the experimental findings during the linear elastic deformation process.

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This paper investigated the failure behaviour of medium thick carbon fibre reinforced aluminium laminates (CARALL) panels under transverse local quasi-static contact crush experimentally and numerically. Four types of CARALL specimens with a 3/2 configuration were manufactured by hot-pressing process using two type of aluminium alloys (2024-T3, 7075-T6 aluminium alloy) and CFRPs with different lay-up ([0°/90°/0°]3, [45°/0°/-45°]3). Three dimensional Hashin progressive failure model in quadratic strain form with damage evolution laws defined by subroutine VUMAT based on ABAQUS was used to simulate the composite layers. The bilinear cohesive contact model was used to predict interfacial failure. Aluminium alloys were defined by Johnson-Cook model. Numerical predictions composing of load-deflection curves and failure mode were matched closely with experimental results. The results of the analysis shown that delamination in CFRP/Al interfaces was the initial damage of the tested CARALL panels. Matrix failure occurred after the delamination closely. The maximum load bearing was determined by fracture of aluminium alloy. Fibre breakage was responsible for complete failure of specimens.