Low velocity impact resistance of hybrid CFRP ‐elastomer‐metal laminates: Influence of stacking sequence and impact conditions on damage mechanisms

Abstract Fiber‐metal laminates (FMLs) are generally regarded as excellent lightweight materials for advanced structure design. To enhance the mechanical properties, the common FMLs can be optimized using carbon fibers. However, the combination of carbon fibers with aluminum induces interfacial challenges. Preventing galvanic corrosion with elastomeric interlayers is an effective solution. The lay‐up configuration greatly effects the impact damage resistance of hybrid CFRP‐elastomer‐metal laminates (HyCEMLs). In this work, micro‐CT scans and optical micrographic inspections on HyCEMLs are conducted after impact tests to ascertain the microstructural origins behind the mechanical performance changes. In addition, finite element models of different HyCEML configurations are built to complement the limited experimental data. The damage mechanisms of HyCEML with different configurations under various impact conditions are further compared. The numerical results suggest that impact energy is a more informative measure in terms of damage mode and size than impact velocity and momentum. Results also indicate that when the thickness for each sub‐laminate of HyCEML is maintained the same, hybrid laminates with aluminum stacked outside is beneficial for delaying the occurrence of matrix cracking and delaminations, and enhances HyCEML's resistance to global deformation. These findings will contribute to engineering hybrid laminates with desired impact performance for lightweight load‐bearing structures. Highlights The hybrid laminate with elastomeric interlayers is a forward‐looking solution in impact applications. Impact energy is a more informative measure in terms of assessing the damage mode and extent in HyCEMLs. The influence of stacking sequence on damage mechanisms of HyCEMLs is evaluated. Microstructural origins behind variations of hybrid laminates in the impact resistance are revealed.