ADVISOR: ENGR.

MUHAMMAD ALI NASIR

(ASSISTANAT PROFESSOR, MED)
FABRICATION/EXPERIMENTAL CHARACTERIZATION
OF ARAMID REINFORCED ALUMINUM
LAMINATES(ARALL)
PROJECT TITILE
Group members

Zeeshan Mehboob 10-ME-23
Waqas Tahir 10-ME-47
Hasnain Afzal 10-ME-77
M Sajid Hussain 10-ME-175
COMPOSITE MATERIAL
Composite materials are engineered materials made from two or more
constituent materials that remain separate and distinct while forming a
single component.
Generally, one material forms a continuous matrix while the other
provides the reinforcement.
The two materials must be chemically inert with respect to each
other.
No interaction occurs upon heating until one of the components
melts, an exception to this condition is a small degree of inter
diffusion at the reinforcement-matrix interface to increase bonding


APPLICATIONS

The aerospace industry (structural components as well
as engines and motors)
Automotive parts (panels, frames, dashboards, body
repairs)
Sinks, bathtubs, hot tubs, swimming pools
Cement buildings, bridges
Surfboards, snowboards, skis
Golf clubs, fishing poles, hockey sticks

Composites:
Multiphase material with significant proportions of each
phase.
Dispersed phase:
Purpose: enhance matrix properties.
Types: particle, fiber, structural

Matrix:
The continuous phase
Purpose is to:
- transfer stress to other phases
- protect phases from environment
Types: MMC, CMC, PMC


5
Terminology/Classification
Classification of Composites
6
Adapted from Fig. 16.2,
Callister & Rethwisch 8e.
HYBRID COMPOSITE
It is actually incorporation of two or more fibres within a single matrix
the resulting material is a hybrid composite.
Hybrid configuration
1. Interply or tow-by-tow:
In which tows of the two or more constituent types of fiber are mixed in
a regular or random manner.
2. Sandwich hybrids, also known as core-shell:
In which one material is sandwiched between two layers of another.
3. Interply or laminated:
where alternate layers of the two (or more) materials are stacked in a
regular manner.
4. Intimately mixed hybrids:
where the constituent fibers are made to mix as randomly as possible
so that no over-concentration of any one type is present in the
material.

FIBER METAL LAMINATES


Fiber metal laminates (FMLs) are hybrid composite structures based on
thin sheets of metal alloys and plies of fiber reinforced polymeric
materials .
ADVANTAGE:
The fiber/metal composite technology combines the advantages of
metallic materials and fiber reinforced matrix systems. Taking
advantage of the hybrid nature from their two key constituents: metals
(mostly aluminum) and fiber-reinforced laminate, these composites
offer several advantages such as better damage tolerance to fatigue
crack growth and impact damage especially for aircraft applications.
FMLS TYPES
ARALL COMPOSITE

In 1978 ARALL has been developed at the Faculty of Aerospace
Engineering at the Delft University of Technology in Netherland.
ARAMID FIBRE RIENFORCED ALUMINUM ALLOY
LAMINATES(ARALL) are a new class of hybrid materials which consist
of alternating layers of thin Isotropic high-strength aluminum alloy
sheets bonded by a structural metal adhesive impregnated with high-
strength aramid fibers.
SCHEMATIC DIAGRAM
APPLICATIONS(ARALL)
Aircraft:
The lower wing skin
The pressure cabin of the fuselage
Lugs
Crack stoppers
GENERAL USES:
Automotive parts (panels, frames
dashboards, body repairs)
Surfboards, snowboards




MANUFACTURING PROCESS
Following are the steps that should b followed to
manufacture the ARALL composite.
1) Cutting
2) Mechanical Degreasing
3) Alkaline degreasing
4) De-oxidation
5) Electrochemical treatment
6) Hand lay up
7) Compression molding
8) Post curing
9) Cutting of sample
CUTTING

Cutting is done by hacksaw from a aluminum sheet.
Grade :2024-T3 ALCLAD
AL clad: putting the al layer on sheet to make it corrosion
free.
Dimensions:
LENGTH: 135mm
WIDTH: 90mm

MECHANICAL DEGREASING
This process is done by following method
Purpose:
We use sand paper to degrease it mechanically for cleaning purposes .we
also use acetone to clean it.
Procedure:
Sand paper grade:800C
We use this grade to remove bigger zig zag scratches on AL parallel to it
length. We check the uniform scratches in unidirectional then move to
further grade.
Sand paper grade:1000C
Now we use this grade to make our specimen more fine in terms of
cleaning scratches in perpendicular to length of specimen
Sand paper grade:1200C
Finally we use this grade to make our specimen ready for alkaline
degreasing.
FIGURE SHOWING
ABRASION
800 Grade Sand Paper 1000 Grade Sand Paper
WATER BREAK TEST
This test method covers the detection of the presence of hydrophobic
(no wetting) films on surfaces and the presence of hydrophobic organic
materials in processing environments. When properly conducted, the
test will enable detection of molecular layers of hydrophobic organic
contaminants. On very rough or porous surfaces, the sensitivity of the
test may be significantly decreased we do this according to ASTM
F22.
We do this test after mechanical abrasion and alkaline degreasing.
ALAKLINE DEGREASING

Purpose:
The purpose of this degreasing is to remove the debris that is embedded
into the specimen surface due to the mechanical abrasion.
we will do the alkaline degreasing of aluminum sheets. For this purpose we
have to make the solution.
Solution:
Sodium hydroxide(NaoH) 11% by weight
De ionized water 89 % by weight
According to ASTM 309 we will put the
specimen into this solution under following conditions
Standards:
Temperature: 43 C
Time: 10 min

ALAKLINE DEGREASING
Before Alkaline
degreasing
After Alkaline Degreasing
DE-OXIDATION

Purpose:
The purpose of this process is to remove the natural oxygen layer from the
specimen so that we can deposit our required controlled alumina layer onto the
specimen
Now will do the do oxidation on these plates for de oxidation we have to make
solution.
Solution:
Na
2
Cr
2
O
7
30 % by weight
H
2
SO
4
10% by weight
De ionized water 60 % by weight
Procedure:
Now we will put the specimen in the beaker containing
this solution and follow the ASTM standard as follows
Standards:
Temperature: 43 C(initially), 80 C(secondary)
Time:10 min

DE-OXIDATION
Before De oxidation After De oxidation
ELECTROCHEMICAL
TREATMENT

Purpose:
Purpose of this process is to deposit the required alumina layer in order to increase
the bonding between aramid fiber and aluminum specimen
Now we will do the electrochemical treatment . For this purpose we will make the
solution as follows.
Solution:
H
3
PO
4
12 % by weight
De ionized water 88 % by weight
Experimental requirements:
Anode: aluminum specimen
Cathode: stainless steel
DC power supply: 15 volts
Time: 15 min
Procedure:
Now will put specimen in beaker and attach it with a power supply this actually
deposits the required oxygen layer on to specimen surface.


ELECTROCHEMICAL
TREATMENT
Before Electrochemical
Treatment
After Electrochemical
treatment
HAND LAY UP
Now we have to make the epoxy YD-128 DOMIDE
Solution of Epoxy:
MIX RATIO:
Resin 65 % by weight
Hardener 35 % by weight
Now we have to mix this mixture and apply on the anodized aluminum
surface and also on aramid fiber by brush.
Purpose:
Purpose of this is to bind the aluminum specimen with aramid fibers
HAND LAY UP
Aluminum surface Aramid fiber
FINAL SHAPE
COMPRESSION MOLDING
After this lay up process we placed the specimen in
compression mold it contains following steps
Steps:
1) Apply the wax on the upper and lower surface of the
mold.
2) Place the specimen on to the surface of mold
3) Put the upper mold
4) Apply uniformly distributed pressure by tightening the 6
screws.
CURING:
Place it in compression mold for 24 hours purpose of
curing
COMPRESSION MOLDING
Step 1 Step 2
Step 3 Step 4
CUTTING OF SPECIMEN
Final cutting is done in IST(institute of space and
technology) by meta cut.
Dimension:
Length: 120mm
Width: 18mm
Thickness: 3.5mm
FINAL SPECIMEN
PREPARATION OF SPECIMEN FOR
TESTING
We apply paints to prepare the specimen for
(digital image correlation)DIC.
Steps:
Firstly apply black paint
Apply white paint (droplets) by sprayer
PREPARATION OF SPECIMEN FOR
TESTING
Black paint White paint
Testing
Four point bending fatigue test will be done
using ASTM STANDARDS D6272 on the
availability of skilled operator of MTS 810.