Experimental and numerical analysis of low-velocity impact and compression after impact responses of novel 3D hybrid composites

Rising environmental concerns and the push to cut carbon emissions have resulted in increased incorporation of lightweight materials to improve fuel efficiency across industries. Fiber Metal Laminates (FMLs), known for superior properties, are widely used in aerospace. In the same vein, the recently developed 3D Fiber-Metal Laminates (3DFMLs) with a 3D composite core have been demonstrated to offer remarkable performance despite fabrication challenges. Two innovative 3D hybrid composites (3DFML-PI and 3DHC-PI) are introduced. These FMLs integrate plastic inserts to overcome the fabrication hurdles experienced by the original 3DFMLs and enhance their mechanical properties. Notably, 3DFML-PI shows comparatively an exceptional impact resistance with a higher perforation threshold, highlighting the efficacy of plastic inserts. Additionally, 3DFML-PI exhibits higher compressive strength, suggesting improved consolidation of the 3D composites. Comparison of the compression-after-impact (CAI) performances also underscores the advantages of high flexural stiffness and localized damage. The research justifies further exploration and implementation of these innovative materials in practical applications requiring lightweight materials with high specific strength, stiffness, impact resistance, and economic sustainability.