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A Novel One-Shot Forming Process Integrating Hot Form Quench (HFQ) of High-Strength Aluminium for Fibre–Metal Laminate (FML) Panel Parts

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Abstract:

Fibre metal laminates (FMLs), combining metal alloy sheets with fibre-reinforced polymers (FRPs), offer high specific strength and good fatigue resistance for lightweight structural applications. However, conventional manufacturing routes for thermoplastic FMLs rely on separately forming and bonding or hot pressing, which involve multi-stage forming routes, long heating cycles, high energy consumption and limited industrial scalability. To address these limitations, a novel non-isothermal one-shot forming route integrating hot form quench (HFQ) with FRP stamp forming is proposed in this study. In this process, separately heated metal and FRP blanks are stamped together in cold tools, enabling simultaneous forming and adhesive-free bonding within a single operation. U-bending forming trials were conducted using AA6082 aluminium alloy sheets and carbon fibre-reinforced polyamide 6 (CF/PA6) laminates. The influence of FRP temperature state and aluminium surface condition on forming quality and interfacial bonding performance was systematically examined. Solid-state FRP forming limited excessive polymer flow, resulting in stable bonding but a higher intra-ply void content, whereas molten-state forming promoted polymer redistribution and reduced void content at the expense of bonding performance, leading to local debonding in highly deformed regions. In addition, chromic acid etching of the aluminium surface improved bonding and mitigated debonding after forming and post-form T6 artificial ageing. These results highlight the importance of balancing polymer flow behaviour and aluminium surface condition in non-isothermal one-shot forming, providing a practical and energy-efficient route for manufacturing thermoplastic FML components.

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Periodical:

Key Engineering Materials (Volume 1051)

Pages:

105-111

DOI:

https://doi.org/10.4028/p-817agE

Citation:

Cite this paper

Online since:

April 2026

Authors:

Chunyi Gao*, Hao Wu, Bamber Blackman, Nan Li

Keywords:

Fiber Metal Laminates, One-Shot Forming, Thermoplastic Composites

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Creative Commons CC BY 4.0

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* - Corresponding Author

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