Available online at ScienceDirect. Procedia Engineering 64 (2013 )

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1 Aville online t ScienceDirect Procedi Engineering 64 (2013 ) Interntionl Conference On DESIGN AND MANUFACTURING, IConDM 2013 Effect of lternte metls for use in nturl fire reinforced fire metl lmintes under ending, impct nd xil lodings M.Vsumthi*, Vel Murli Engineering Design Division, Deprtment of Mechnicl Engineering, College of Engineering, Guindy, Ann University, Chenni , Indi Astrct Fire Metl Lminte (FML) is lrgely used in the mnufcture of ircrfts. The commercilly ville FMLs, GLARE, CARALL (CAron Reinforced ALuminium Lminte) nd ARALL mke use of Aluminium metl. Other FMLs tht re under study y reserchers mke use of metls such s Titnium nd Mgnesium sed lloys. Owing to the high cost of cron fire nd the necessity for environment friendly lterntives, in the present work, portion of cron is replced y nturl fire jute in CARALL nd CARMAL (CAron Reinforced MAgnesium Lminte). To the knowledge of the uthors, this ttempt hs not een mde efore in the field of FMLs. The resulting CAron-Jute Reinforced ALuminium Lminte nd CAron-Jute Reinforced MAgnesium Lminte re nmed s CAJRALL nd CAJRMAL. Both these lmintes re mde y hnd lyup technique nd then compressed in compression moulding mchine. The CAJRALL nd the CAJRMAL specimens re sujected to Axil, Flexure nd Impct tests ccording to ASTM stndrds. The effect of the orienttions of fires nd influence of the stcking sequences of the fire nd metl comintions nd the use of lternting metls on the mechnicl performnce, re experimentlly investigted. The experimentl nd theoreticl results s well s the results otined through Finite Element Anlysis re found to e in close greement. Also the filure of the FML is predicted y conducting micro level structure nlysis The Authors. Pulished y Elsevier Ltd. Open ccess under CC BY-NC-ND license. Selection nd peer-review under responsiility of the orgnizing nd review committee of IConDM Keywords: Fire Metl Lminte (FML); Jute; CAJRALL; CAJRMAL; Mechnicl ehviour * Corresponding uthor. Tel.: ; fx: E-mil ddress: vsumthi@nnuniv.edu The Authors. Pulished y Elsevier Ltd. Open ccess under CC BY-NC-ND license. Selection nd peer-review under responsiility of the orgnizing nd review committee of IConDM 2013 doi: /j.proeng

2 M.Vsumthi nd Vel Murli / Procedi Engineering 64 ( 2013 ) Introduction After World wr-ii, plenty of chnges hve tken plce in the re of mteril reserch. Owing to the process of depletion of trditionl metls, such s steel, cst iron, luminium, zinc, copper, mgnesium, titnium nd their lloys, new technologies re eing evolved y mteril nd design engineers, y inventing new ctegory of mterils nmed composites, which re formed y comining different metls. Even though the purpose of the invention of the composite ws different, it turned out to e welcome move, s it resulted in low weight mteril. Lter on, severl ides were developed to crete composites with much lower density, using fires such s cron nd glss insted of the conventionl metls. Even though, cron nd glss possessing high strength were le to replce the conventionl metls, the world welcomed nturl fires in the sphere of composites [1], s they re sfe unlike synthetic fires which cuse helth hzrds nd help to crete green environment. Tody, mterils reserch is moving towrds nturl fire composites/lmintes. It is ecuse of fctors such s nture, iodegrdility with respect to fire, nd redy use of plnts / trees with less processing. The nturl fiercontining composites, possessing noticele properties on pr with mn-mde fires, re used in trnsporttion (utomoiles, rilwy coches, nd erospce), militry, uilding nd construction industries (ceiling pneling, prtition ords), pckging etc. Rndomly directed fires were employed in the formtion of these nturl fire composites. Lter, these nturl fires were given surfce tretment with lkline solutions, to prove their worth in dvnced mechnicl pplictions [2-4]. This trend developed, nd led to the reinforcement of fires in the form of lmintes. These lminted composites showed significnt properties in comprison with rndom oriented composites. Lter, in the life cycle of the composite mteril, ppered new form of composite, wherein the fire is reinforced with metl, so s to inherit specil properties in order tht it cn e used in the erospce industry. A Fire Metl Lminte (FML) ws originlly developed t the Delft University of Technology. It consisted of thin sheets of luminium, onded with fire dhesive lyers. This lminted structure ehves much the sme s simple metl structure, ut with considerle specific dvntges with regrd to properties, such s metl ftigue, impct, corrosion resistnce, fire resistnce, weight svings nd specilized strength properties. Some of the commercilly ville FMLs such s GLARE (GLAss Reinforced Epoxy lminte), ARALL (Armid Reinforced ALuminium Lminte) nd HTCL (Hyrid Titnium Composite Lminte) hve significnt properties tht re useful in the vition field [5-6]. Asundi. A, et l [7] investigte fire metl lmintes with respect to the splicing concept. The splicing concept offers enefit for regulr FML pnel except for wider pnels. This incresed width cpility cn result in significnt reduction in mnufcturing cost. Sinke J, et l [8] investigte the detiled ehviour of fire lyer to hve etter understnding of its filure mode. Summerscles J. et l [9] investigte the mechnicl properties of et l [10] try to find n improved process for the mnufcture of fire metl lmintes. This work outlines simple, cost effective nd widely dptle process for the mnufcture of fire metl lmintes. Here, the metl surfce is roughened with grit lsting for effecting strong ond etween metl nd fire cloth dhesive lyers (prepreg). Xun Xu, et l [11] consider nturl fires such s sisl, flx, jute nd wood-fires which possess good reinforcing cpility when properly compounded with polymers. So fr, studies hve een mde on FMLs such s GLARE, ARALL, HTCL nd lso on FMLs, mnufctured with mn-mde fires reinforced with other metls, such s mgnesium nd titnium [12-14], in eronuticl pplictions. According to Cortes et l, FMLs re cple of soring significnt energy through loclized fire frcture nd sher filure in the metl plies [13]. Also the interfce onding etween the composite nd the metl plies, tensile ehviour nd low velocity impct studies were performed on these FMLs [14]. To ring down the cost of fires such s cron nd glss, nd for the ske of pollution-free environment, n ttempt is mde in this work y ringing in nturl fire, Jute, cost effective nd eco-friendly fire, into the FML. Jute is lingo-cellulosic fire tht flls into the st fire ctegory like kenef, hemp, flx, rmie etc. It elongs to the fmily of Sprrmnnicee. It requires plin lluvil soil with stnding wter, moderte wrm nd wet climte with tempertures rnging from 20 C to 40 C nd reltive humidity of 70% to 80%, for successful cultivtion. This fire hs een n integrl prt of the culture of Bengl, Bngldesh nd some portions of West diverse sectors of industries, where

3 564 M.Vsumthi nd Vel Murli / Procedi Engineering 64 ( 2013 ) nturl fires re grdully ecoming etter sustitutes. Its production is concentrted in Indi nd Bngldesh, s per yer (during 2011), next to Bngldesh [15]. It is 100% io-degrdle, recyclle, nd thus environment friendly fire. Tle 1. Properties of Metls nd Jute fire used in FML Property Aluminium Mgnesium Jute Fire Density (Kg/m 3 ) Tensile Strength (MP) Elongtion (%) In the present work, n ttempt is mde for the first time, to replce portion of cron fire with nturl fire jute. Also the influence of lternte metl, mgnesium on the mechnicl performnce of the FML is studied. The ide of utilizing mgnesium metl in plce of luminium hs risen due to its cpturing property, low density. It is notle tht mgnesium is 1.55 times lighter thn luminium nd hence it results in reduction in weight of the existing FMLs. The resulting FMLs re nmed s CAJRALL (CAron-Jute Reinforced ALuminium Lminte) nd CAJRMAL (CAron-Jute Reinforced MAgnesium Lminte). The ehviour of CAJRALL nd CAJRMAL re exmined when they re sujected to tensile, flexure nd impct tests. Their experimentl findings re vlidted with FE simultion. Moreover, theoreticl evlution of the tensile prmeters is executed nd these re compred with experimentl nd simulted results. Also micro level exmintion of the CAJRMAL is performed for the xilly nd impct loded specimens to nlyse their pttern of filure. The mechnicl properties of the metls nd the jute fire re listed in the Tle Mterils nd FML friction 2.1. Mterils used for lminte preprtion The mterils utilized for the preprtion of the FML smples re cron (300 gsm) nd jute (200 gsm) fires, luminium 2024 T3 sheet with thickness of 0.19 mm, mgnesium AZ31 sheet with thickness 0.25 mm, epoxy resin of grde LY 556 nd Arldite hrdener of grde HY CAJRALL nd CAJRMAL mnufcture The lminte to e tested for different ehviors such s tensile, flexure nd impct re prepred with vrying stcking orders of fires nd metl sed on the direction of loding. The CAJRALL specimens considered for tensile test re oriented with stcking sequences of (Al/C 0 /Al/Ju 0 /Ju 90 /Al/C 0 /Al) nd (Al/ C 0 /Al/Ju 0 /Ju 90 /Al/C 90 ) S. The CAJRALL specimens to e sujected to Flexure test re stcked in the orders of (C 0 /Al/ C 0 /Ju 0 /Ju 90 /C 0 /Al/C 0 ) nd (C 0 /Al/ C 0 /Al/Ju 0 /Ju 90 /Al/C 0 /Al/C 0 ). Here the cron fire is plced in the top nd ottom lyers of the lminte, s it hs high ending resistnce when compred to other mterils in the lminte. The specimens for Impct test re rrnged in qusi-isotropic stcking sequence of (C 0 /Al/C 45 /Al/Ju 0 /Ju 90 /Al/C -45 /Al/C 0 /Al/C -45 /Al/Ju 0 /Ju 90 /Al/C -45 ) nd vrying sequence of (C 0 /Al/C 90 /Al/Ju 0 /Ju 90 /Al/C 90 Al/C 0 /Al/C 90 /Al/Ju 0 /Ju 90 /Al/C 90 /Al). The CAJRMAL specimens re prepred y just replcing the Aluminium y Mgnesium in the ove mentioned stcked lmintes. The lmintes

4 M.Vsumthi nd Vel Murli / Procedi Engineering 64 ( 2013 ) rrnged s ove re lended with epoxy resin through hnd ly-up technique. Then they re cured t room temperture nd compressed for ten minutes in the compression molding mchine t pressure of 70 kg cm -2 nd t temperture of 70 C nd thus the finl FML is otined. 3. FML response under xil, ending nd impct lodings 3.1 Axil loding The CAJRALL nd CAJRMAL specimens fricted s ove for the tensile test re cut nd tested ccording to ASTM D 3039 stndrd in the INSTRON 3369 Universl Testing Mchine nd the test findings re shown in Fig. 1. () nd (). 3.2 Flexure loding Fig. 1. Plot of () Tensile strength The CAJRALL nd CAJRMAL specimens fricted s ove for the flexure test re cut nd tested ccording to ASTM D790 stndrd in the three point ending test set-up nd the test findings re given in Fig. 2. () nd (). Fig. 2. Illustrtion of () Bending strength nd () Flexure Modulus for CAJRALL nd CAJRMAL specimens.

5 566 M.Vsumthi nd Vel Murli / Procedi Engineering 64 ( 2013 ) Impct loding The CAJRALL nd CAJRMAL specimens fricted s ove for the impct test re cut nd tested ccording to ASTM D 7136 stndrd in the Izod impct test set-up nd the test findings re shown in Fig. 3. Fig. 3. Plot of Impct Toughness for CAJRALL nd CAJRMAL specimens. 3.4 Tensile properties of individul plies in CAJRALL nd CAJRMAL lmintes To determine theoreticl vlues of stress in individul lyers of cron, jute, luminium, mgnesium nd lso in the totl lminte s well s for the execution of Finite Element Anlysis of the FMLs, the tensile prmeters of the FMLs These prmeters re evluted for cron-epoxy nd jute epoxy lmintes, with cron nd jute fires oriented seprtely in 0 nd 90 directions nd re tulted in Tle 2. The stress vlues in the individul lyers otined using stress-strin reltion nd equtions (1) nd (2), re outlined in Fig. 4. () nd (). Tle 2. Tensile properties of individul plies in CAJRALL Property Cron 0 Cron 90 Jute 0 Jute 90 E 11(GP) E 12(GP) μ μ G (GP) The strin mtrix is given y x y xy 1 /mm 2 (1) where [A] = [Q] t, is the extensionl stiffness mtrix, t is the thickness of the lminte nd Q is the reduced stiffness mtrix.

6 M.Vsumthi nd Vel Murli / Procedi Engineering 64 ( 2013 ) x y xy / mm (2) Fig. 4. Comprison of xil stress vlues () CAJRALL nd () CAJRMAL. 4. Anlysis using FEM The CAJRALL nd CAJRMAL specimens re modelled in ANSYS nd ABACUS softwres to simulte tensile nd flexure performnces. The results of tensile nlysis of CAJRALL nd CAJRMAL re shown in Fig. 5. () nd () respectively. The tensile stress for 8 lyered nd 13 lyered CAJRMAL specimens re found to e MP nd MP respectively nd tht of CAJRALL re 158 MP nd 194 MP respectively. On the other hnd, the ending resistnces of the 8 lyered nd 10 lyered CAJRMAL specimens re found to e MP nd MP respectively nd tht of CAJRALL re 525 MP nd 315 MP respectively. Fig. 5. Illustrtion of FEM nlysis of Axil loding of () CAJRALL nd () CAJRMAL.

7 568 M.Vsumthi nd Vel Murli / Procedi Engineering 64 ( 2013 ) Results nd Discussion Fig. 1. () nd () shows the experimentl results of xilly loded CAJRALL nd CAJRMAL specimens. The tensile stress for 8 nd 10 lyered CAJRALL re found to e MP nd MP respectively nd tht of CAJRMAL re MP nd lyered CAJRALL re otined s 4.71 GP nd 3.74 GP respectively nd tht of CAJRMAL re 4.35 GP nd 3.3 GP respectively. The results otined when sujecting the CAJRALL nd CAJRMAL specimens to ending re illustrted in Fig. 2. () nd (). The flexure strength of the 8 nd 10 lyered CAJRALL re found to e MP nd MP respectively nd tht of CAJRMAL re MP nd MP respectively. Further the flexure modulus of the 8 nd 10 lyered CAJRALL re oserved s 1.71 MP nd 1.54 MP respectively nd tht of CAJRMAL re 1.45 MP nd 1.29 MP respectively. Fig. 3. demonstrtes the results of impct loded CAJRALL nd CAJRMAL specimens. The resulting impct toughness of the qusi-isotropic oriented CAJRALL nd CAJRMAL specimens re x10-4 J/mm 3 nd x10-4 J/mm 3 respectively nd tht of generlly stcked CAJRALL nd CAJRMAL specimens re x10-4 J/mm 3 nd x10-4 J/mm 3 respectively. From Fig. 1.() nd (), it is seen tht the tensile strength of the CAJRALL nd CAJRMAL mterils increse Moreover, s the numer of lyers increse, the flexure resistnce of the CAJRALL nd CAJRMAL mterils decrese nd this is evident from Fig. 2. () nd (). It cn e viewed from Fig. 3 tht the impct toughness of the CAJRALL nd CAJRMAL mterils hs decresing trend for Specimen II when compred to Specimen I. Further, it my e noted tht the experiment results of the FMLs closely mtch with the nlyticl nd theoreticl results with mximum vrition of 11% nd 13 % respectively for CAJRALL nd 12% nd 9% for CAJRMAL specimens. 5.1 Microstructure Anlysis for chrcteriztion of dmge in the CAJRMAL specimens In order to chrcterize the frcture surfce of the vrious CAJRMAL smples, microstructure nlysis is crried out using Scnning Electron Microscope (SEM). It is oserved from Fig. 6. () nd (), the filure of the xilly loded CAJRMAL specimens re mostly due to jute fire elongtion nd pull out. Also it cn e mentioned tht tensile specimens re prone to delmintion i.e., detchment of lyers from ech other, which leds to filure. The impct dmge mechnism in the CAJRMAL lminte constitutes very complex process. It is comintion of mtrix crcking, surfce uckling, delmintion, fier sher out/ pull out nd fier frcture, s illustrted in Fig. 7. () nd (), tht usully interct with ech other. The sequence of filure of CAJRMAL specimen is noted with the strt of mtrix crcking, then filure of the jute fire, delmintion, cron frcture nd finlly mgnesium ductile elongtion nd frcture. Jute fire pull out Delmintion Fig. 6. SEM imges of xilly loded, frctured CAJRMAL specimens () Fire pull out nd () Delmintion etween lyers.

8 M.Vsumthi nd Vel Murli / Procedi Engineering 64 ( 2013 ) M.Vsumthi, Vel Murli / Procedi Engineering00 (2013) Mtrix crcking Mgnesium ductile frcture Fig. 7. SEM photogrphs of frctured CAJRMAL specimens under impct loding () Mtrix crcking nd () Ductile elongtion of mgnesium 6. Conclusions In the present work, in CAron Reinforced ALuminium Lminte (CARALL), portion of cron fire is replced y nturl fire jute, owing to the high cost of cron nd to provide pollution-free environment nd its mechnicl performnce is nlysed. Also, owing to low weight property of the FMLs, n ttempt is mde in CAJRALL, y replcing luminium with mgnesium metl. It is oserved tht the tensile nd flexure stresses of CAJRALL nd CAJRMAL re directly proportionl nd the Flexure modulus is inversely proportionl to the numer of lyers. Moreover, the CAJRALL with (C 0 /Al/C 45 /Al/Ju 0 /Ju 90 /Al/C -45 /Al/C 0 /Al/C - 45 /Al/Ju 0 /Ju 90 /Al/ C -45 ) rrngement nd CAJRMAL with the sme rrngement ut replced with mgnesium metl hve etter impct resistnce. Also the experiment findings re in close greement with nlyticl nd theoreticl results with mximum vrition of out 11% nd 13% for CAJRALL nd 12% nd 9% for CAJRMAL FMLs respectively. The microstructure study revels tht the predominnt filure mechnisms in xilly loded CAJRMAL specimen re found to e fire pull out nd delmintion etween lyers nd in impct loded specimens, it is mtrix crcking. Since mgnesium is 1.55 times less hevy thn luminium nd lso not much difference is oserved from the results of the mechnicl response of CAJRMAL, it is evident tht, it is eneficil to use CAJRMAL in plce of CAJRALL in pplictions tht essentilly require low weight mterils. References [1] Murli Mohn Ro, K., Mohn Ro,K., Rtn Prsd, A.V., Friction nd testing of nturl fier composite: Vkk, Sisl, moo & nn, Mterils & Design 31, p [2] Vsumthi, M., Vel Murli., Frcture ehvior of chemiclly treted reshir-epoxy composite nd optimiztion of prmeters for composite friction, Advnced Mterils Reserch , p [3] Vsumthi, M., Vel Murli., Mechnicl ehvior of chemiclly treted reshir-epoxy composite t cryogenic tempertures, Advnced Mterils Reserch , p [4] Vsumthi, M., Vel Murli., Mechnicl chrcteriztion of chemiclly treted vetiver-epoxy composite, Interntionl Journl of Applied Engineering Reserch 6, p [5] Botelho, E.C., Silv, R.A., Prdini, L.C., Rezende, M.C., A review on development nd properties of continuous fier/epoxy/luminium hyrid composites for ircrft structures, Mterils Reserch 9, p [6] Roeroeks, G.H.I.J., Fier-metl lmintes recent developments nd pplictions, Ftigue 16, p. 33. [7] Asundi, A., Alt choi., Fire Metl Lmintes: An Advnced Mteril for Future Aircrft, Journl of Mterils Processing Technology 63, p [8] Sinke, J., De Vries, T.J., Vn Der Zwg, S., The Bering Strength of Fire Metl Lmintes, Journl of Composite Mterils 40, p. 5. [9] Summerscles

9 570 M.Vsumthi nd Vel Murli / Procedi Engineering 64 ( 2013 ) [10 -Effective Approch for the Mnufcture of Fire Metl Lmintes (F - Proceedings of the Interntionl Conference on Aerospce Science nd Technology, pp [11] Xun Xu, Krishnn Jyrmn, Croline Morin, Nicols Pecqueux, Life cycle ssessment of wood-fire-reinforced polypropylene composite, Journl of Mterils Processing Technology 198, p [12] Cortes, P., Cntwell, W.J., Structure-properties reltions in titnium-sed thermoplstic fier-metl lmintes, Polymer Composites, p [13] Cortes, P., Cntwell, W.J., The prediction of tensile filure in titnium-sed thermoplstic fier-metl lmintes, Composite Science Technology 66, p [14] Cortes, P., Cntwell, W.J., Frcture properties of fier-metl lmintes sed on mgnesium lloy, Journl of Mteril Science 39, p [15]