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![]() Title:Development of Hybrid Metal Continuous Carbon Fiber Reinforced Composites via Additive Manufacturing for Near Net Shape Products Conference:ICASET 2025 Tags:Additive Manufacturing (AM), Continuous Carbon Fiber Reinforced Thermoset Composites (CCFRTC), Fiber Metal Laminate (FML) and Near Net Shape Abstract: Integrating additive manufacturing (AM) with continuous carbon fiber-reinforced thermoset composites (CCFRTCs) offers significant potential for producing high-performance, near-net-shape composite structures with tailored mechanical properties. This study explores the development of additively manufactured hybrid fiber metal laminate (FML), combining the lightweight and high strength of brittle CCFRTC with the ductile aluminum metal. Additive deposition of reactive resin-infused fiber tow (ADRRIFT) process is employed to print a composite on a surface-treated metal substrate, with a strong interfacial bond for load transfer. This enables significant increases in design and manufacturing complexity, allowing for faster prototyping of efficient and multifunctional structures. The research investigates processing parameters, fiber-metal adhesion, and mechanical performance under impact loading. The results revealed that the mechanical properties are highly dependent on the fiber architecture, the metal and polymer composite interface, and the interlaminar strength of the polymer composite. FML impacted at 30 J exhibited up to 76% increase in peak load, 13% increase in absorbed specific energy, and 11% increase in density compared to the AM monolithic composite. Furthermore, this work lays the foundation for advancing hybrid metal composites through the ADRRIFT process, enabling the creation of complex geometries with freedom of material and fiber architecture not possible with conventional manufacturing processes. Development of Hybrid Metal Continuous Carbon Fiber Reinforced Composites via Additive Manufacturing for Near Net Shape Products ![]() Development of Hybrid Metal Continuous Carbon Fiber Reinforced Composites via Additive Manufacturing for Near Net Shape Products | ||||
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