Comparisons of the Performance of Novel Lightweight Three-Dimensional Hybrid Composites against GLARE Fiber–Metal Laminate

Abstract

The objective of the work presented in this paper is to overcome several major shortcomings of the recently introduced 3D composites (3DCs) and their fiber–metal-laminate renditions (3DFMLs). A new class of lightweight, stiff, and resilient three-dimensional hybrid composites (3DHCs) is introduced in this study, referred to as “inserts enhanced 3D hybrid composites” (IE3DHCs). The performances of all configurations were characterised by conducting three-point flexural tests using a span-to-thickness ratio of 32:1. The flexural performance of 3DFMLs with different core thicknesses was first compared using GLARE-3/2-0.4 as a baseline, revealing the superior performance of 3DFMLs; the optimal performance was exhibited by 3DFML with a 3 mm 3DC core. However, the lower ductility of 3DFMLs, as well as their poorly controlled and time-consuming fabrication process were recognized. The newly developed materials (IE3DHCs) had a comparatively simpler fabrication processes with significantly higher quality control. More importantly, IE3DHCs exhibited an approximately 160% improvement in ductility and as much as a 250% improved design strength compared to 3DFMLs. These findings showcase the promising potential of IE3DHCs for future research and real-world applications. Additionally, robust finite element models were developed to simulate flexural tests and optimize future renditions of the IE3DHCs.