Ultrasonic-assisted preparation-forming-curing process for ultra-thin micro-fiber metal laminates: Deformation characteristics

At present, Fiber metal laminates (FMLs) are mostly used in the aeronautical field to manufacture large-size components, such as skins of fuselage or wing. However, the utilization of FMLs in microsystems and micro-electro-mechanical systems has not been explored yet. Therefore, miniaturization of conventional FMLs and integration of micro-sheet preparation and complex-shaped components forming are of utmost significance from a practical viewpoint. Herein, an integrated ultrasonic-assisted preparation-forming-curing method is proposed to manufacture ultra-thin micro-Ti/Cf/PPS hybrid laminates (TA1/Carbon fiber/PPS) components in this paper. The influence of ultrasonic vibrations on the performance of as-prepared micro-laminates is systematically studied, including the immersion distribution of PPS resin in Cf layer, interfacial bonding properties of Cf/PPS and Ti/PPS interfaces and micro-deformation mechanism of metallic layer. Furthermore, the hot bulging test is carried out by rapid transfer of the micro-laminates at melting temperature (280 °C) of the resin layer using a micro-arrayed spherical-cap die to assess the formability. A combination of electron backscatter diffraction (EBSD) analysis, metallographic observations and image precision measurement revealed the unique deformation characteristics and thickness evolution of complex-shaped micro-Ti/Cf/PPS laminates. Overall, a high deformation level is achieved during the bulging process. The current study provides an enhanced understanding of ultrasonic-assisted micro-forming-curing process.