Multi-Layer Aluminum–Polymer Hybrid Structures for Improved Automotive Impact Performance

Year : 2026 | Volume : 14 | Issue : 02 | Page : 42 53
    By

    Nantha kumar P,

  • K. Arun,

  • Sachin S. Harak,

  • M.Suresh Kumar,

  • DVSSSV Prasad,

  • K. Amudha,

  • Jayarenjini N,

  • V. Kavimani,

  • A. Vijayalakshmi,

  1. Associate Professor, Department of Mechanical Engineering, Sri Sairam Engineering College, Chennai, Tamil Nadu, India
  2. Associate Professor, Department of Mechanical Engineering, St. Joseph’s College of Engineering, Old Mahabalipuram Road, Chennai, Tamil Nadu, India
  3. Professor, Department of Mechanical Engineering, Late GN Sapkal College of Engineering, Nashik, Maharashtra, India
  4. Associate Professor, Department of Mechanical Engineering, St.Ann’s College of Engineering & Technology, Chirala, Andhra Pradesh, India
  5. Professor, Department of Mechanical Engineering, Aditya University, Surampalem, Andhra Pradesh, India
  6. Associate Professor, Department of Science and Humanities-Physics, R. M.D. Engineering College (An Autonomous Institution), Kavaraipettai, Tamil Nadu, India
  7. Professor, Department of Electronics and Communication Engineering, Vidya Academy of Science and Technology Technical Campus, Kilimanoor, Thiruvananthapuram, Kerala, India
  8. Associate Professor, Department of Chemistry, Prathyusha Engineeeing College, Thiruvallur, Tamil Nadu, India
  9. Professor, Department of Chemistry, R.M.K. Engineering College, Kavaraipettai, Tamil Nadu, India

Abstract

Layered metal–polymer hybrid laminates have emerged as promising candidates for lightweight automotive structures requiring high impact resistance and structural reliability. In this study, aluminum/glass–epoxy hybrid laminates were fabricated using a symmetric stacking sequence through hot compression molding to evaluate their mechanical and energy absorption performance. Density analysis revealed an average measured density of 2.34 g/cm³, closely matching the theoretical value of 2.36 g/cm³, with a deviation of approximately 1.02%, indicating effective consolidation. The calculated void fraction remained below 2% (average 1.02 ± 0.45%), confirming minimal internal defects and strong interfacial bonding. Tensile testing demonstrated a nonlinear stress–strain response characterized by initial elastic deformation followed by gradual yielding of aluminum layers, resulting in enhanced load-sharing capability and delayed failure. The hybrid laminates exhibited substantially higher tensile strength than monolithic aluminum of equivalent thickness, accompanied by progressive fracture rather than brittle collapse. Under three-point bending, the laminates displayed high initial stiffness and sustained increasing loads even after the onset of localized yielding and matrix cracking, highlighting efficient stress transfer across layers. Low-velocity impact tests conducted at energies ranging from 10 to 40 J revealed multi-stage damage evolution. At lower energies, localized denting dominated, while higher energies produced controlled delamination and fiber fracture without complete penetration. This behaviour demonstrates superior energy absorption and damage tolerance compared to conventional composites. Overall, the developed hybrid laminates exhibit an optimal balance of stiffness, strength, and impact resistance, making them strong candidates for next-generation automotive body panels requiring lightweight yet crashworthy materials.

Keywords: Hybrid laminates, void fraction, fiber fracture, Layered metal–polymer, automotive body

[This article belongs to Journal of Polymer & Composites ]

How to cite this article:
Nantha kumar P, K. Arun, Sachin S. Harak, M.Suresh Kumar, DVSSSV Prasad, K. Amudha, Jayarenjini N, V. Kavimani, A. Vijayalakshmi. Multi-Layer Aluminum–Polymer Hybrid Structures for Improved Automotive Impact Performance. Journal of Polymer & Composites. 2026; 14(02):42-53.
How to cite this URL:
Nantha kumar P, K. Arun, Sachin S. Harak, M.Suresh Kumar, DVSSSV Prasad, K. Amudha, Jayarenjini N, V. Kavimani, A. Vijayalakshmi. Multi-Layer Aluminum–Polymer Hybrid Structures for Improved Automotive Impact Performance. Journal of Polymer & Composites. 2026; 14(02):42-53. Available from: https://journals.stmjournals.com/jopc/article=2026/view=238597


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Regular Issue Subscription Original Research
Volume 14
Issue 02
Received 12/02/2026
Accepted 23/02/2026
Published 09/03/2026
Publication Time 25 Days
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