Assessing the failure mechanisms and mechanical performance of Co-moulded hybrid AA5182-O/GFRP hat-channel beams under quasi-static three-point bending

In this study, a hot press co-moulding technique was investigated for the fabrication of hybrid metal/composite components. The manufactured hat-channel beams comprise pre-bent AA5182-O aluminum alloy sheet and laminated glass fiber-reinforced plastic (GFRP) layers. Opto-digital microscopy was used to characterize the microstructure of the co-moulded beams and to investigate linkages between the microstructure and manufacturing process. Furthermore, the mechanical performance of baseline aluminum beams and the hybrid co moulded beams under quasi-static three-point bending loads was examined. Two different loading configurations were considered to place the hybridized section either adjacent to the loading tup or on the face of the beam away from the loading tup. The results revealed that the greatest benefit was achieved when the composite section was placed on the side in contact with the loading tup, which resulted in an increase in the strength and absorbed energy of 130% and 90%, respectively, for a 20% weight gain.