Fatigue condition monitoring of notched thermoplastic-based hybrid fiber metal laminates using electrical resistance measurement and digital image correlation

Abstract

In this work, the monitorability of fatigue damage in notched thermoplastic-based hybrid fiber metal laminate, containing AA6082-T4 sheets and glass and carbon fiber-reinforced polyamide 6, is investigated using constant amplitude tests. Electrical resistance measurement and digital image correlation were combined to determine the initiation and evolution process of fatigue damage. Preliminary to the application of the electrical resistance measurement during fatigue load, basic investigations regarding necessary measurement accuracy and conditions, e.g. temperature and cross-section influence, were conducted to achieve reliable measurement results. Via digital image correlation fatigue crack growth was determined and correlated with the change in electrical resistance for two metal/fiber-reinforced polymer layer configurations (2/1 and 3/2) and notch geometries (drilling hole and double-edge notch). The results show that reliable detection of fatigue-related damage states is possible independent of aluminum sheet treatment (mechanically blasted or anodized surface), with earlier crack initiation and faster propagation for higher metal volume fraction (layer configuration 2/1). For the two investigated notch geometries an overall similar crack behavior was found. The electrical resistance values directly correlate to varieties of crack formation and growth, representing the aluminum sheet damage progress of the laminate well, and enabling the possibility of e.g. a limit value-based failure criterion. However, geometry and crack-related changes in electric current flow and thus current density must be taken into account for targeted monitoring of the laminate condition, as they cause significant changes in electrical resistance.