Towards 3D Process Simulation for In Situ Hybridization of Fiber-Metal-Laminates (FML)

Fiber-metal-laminates (FML) provide excellent fatigue behavior, damage tolerant properties, and inherent corrosion resistance.To speed up manufacturing and simultaneously increase the geometrical complexity of the produced FML parts, Mennecart et al. proposed a new single-step process combining deep-drawing with infiltration (HY-LCM). Although the first experimental results are promising, the process involves several challenges, mainly originating from the Fluid-Structure-Interaction (FSI) between deep-drawing and infiltration. This work aims to investigate those challenges to comprehend the underlying mechanisms. A new close-to-process test setup is proposed on the experimental side, combining deep-drawing of a hybrid stack with a linear infiltration. A process simulation model for FMLs is presented on the numerical side, enabling a prediction of the dry molding forces, local Fiber Volume Content (FVC) within the three glass fiber (GF) interlayers, and simultaneous fluid progression. The numerical results show that the local deformation of the hybrid stack and required forces are predictable. Furthermore, lateral sealing of the hybrid stacks leads to deviations from the intended initially one-dimensional fluid progression. Eventually, the numerical results demonstrate that most flow resistance originates from geometrically critical locations. Future experimental and numerical work will combine these insights to focus on the flow evaluation during deformation and a successful part-level application.