Carbon-Al Synergy: Investigation of Fiber Stacking and Orientation on the Mechanical Properties of Al-CFRP Metal Matrix Composites

Year : 2025 | Volume : 13 | Special Issue 05 | Page : 340 354
    By

    Ganesan S.,

  • Saranraj I,

  • Sravanth Chandaka,

  • U Indra Sai,

  • Sai Nadu Teja,

  • Rexith Reginmons,

  1. Professor, Department of Aeronautical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Chennai, Tamil Nadu, India
  2. Assistant Professor, Department of Mechanical Engineering, Mahendra College of Engineering, Salem, Tamil Nadu, India
  3. Student, Department of Aeronautical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Chennai, Tamil Nadu, India
  4. Student, Department of Aeronautical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Chennai, Tamil Nadu, India
  5. Student, Department of Aeronautical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Chennai, Tamil Nadu, India
  6. Student, Department of Aeronautical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Chennai, Tamil Nadu, India

Abstract

The current study examines the mechanical behaviour of Aluminum-Carbon Fiber Reinforced Polymer (Al-CFRP) composites fabricated using compression moulding technique, a novel approach combining lightweight aluminium’s ductility with CFRP’s high strength-to-weight ratio. The polymer composites were fabricated by stacking aluminum alloy sheet of 0.5mm thickness and pre-impregnated by 12 layers of carbon fiber cloth of 200 gsm, with epoxy resin between layers, followed by consolidation under controlled temperature and pressure in a compression moulding setup, ensuring strong interfacial bonding. A comprehensive mechanical characterization was conducted to evaluate the composite’s toughness and structural performance. Results demonstrated that the compression-moulded Al-CFRP composites exhibited enhanced mechanical strength and great stiffness compared to monolithic aluminum, with significant improvements in impact resistance and fatigue life. However, interfacial delamination and fiber buckling were identified as dominant failure modes under extreme loading conditions. This study offers important findings regarding the design and production of non-structural high-performance Al-CFRP metal composites for aerospace, automotive, and defence applications, where weight and formability are crucial than high strength. The results highlight the potential of compression moulding as a viable technique for producing cost-effective, high-strength hybrid composites with tailored properties.

Keywords: Al-CFRP, mechanical characterisation, toughness, metal matrix composites, failure analysis.

[This article belongs to Special Issue under section in Journal of Polymer and Composites (jopc)]

How to cite this article:
Ganesan S., Saranraj I, Sravanth Chandaka, U Indra Sai, Sai Nadu Teja, Rexith Reginmons. Carbon-Al Synergy: Investigation of Fiber Stacking and Orientation on the Mechanical Properties of Al-CFRP Metal Matrix Composites. Journal of Polymer and Composites. 2025; 13(05):340-354.
How to cite this URL:
Ganesan S., Saranraj I, Sravanth Chandaka, U Indra Sai, Sai Nadu Teja, Rexith Reginmons. Carbon-Al Synergy: Investigation of Fiber Stacking and Orientation on the Mechanical Properties of Al-CFRP Metal Matrix Composites. Journal of Polymer and Composites. 2025; 13(05):340-354. Available from: https://journals.stmjournals.com/jopc/article=2025/view=224540


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Special Issue Subscription Original Research
Volume 13
Special Issue 05
Received 17/06/2025
Accepted 19/07/2025
Published 29/07/2025
Publication Time 42 Days
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