Integrated Forming and Curing of Semi-Cured Fiber Metal Laminates Using a Solid Granule Medium

  • DU, Bing
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    1. 1 National-Local Joint Engineering Research Center for Advanced Manufacturing, Forming Technology and Equipment, Yanshan University, Qinhuangdao 066004, China
    2. 2 Key Laboratory of Advanced Forging & Stamping Technology and Science, Ministry of Education of China, Yanshan University, Qinhuangdao 066004, China
    3. 3 Hebei Engineering Technology Research Center of Metal Precision Plastic Processing, Yanshan University, Qinhuangdao 066004, China

Received date: 2025-12-03

  Revised date: 2026-09-10

  Accepted date: 2026-09-11

  Online published: 2026-09-11

Abstract

Fiber metal laminates (FMLs) combine the performance advantages of metallic and composite materials; consequently, they have broad application potential in aerospace and aviation. However, their limited formability after complete curing hinders the one-step fabrication of components with complex curved geometries, thereby restricting their potential for integrated design and manufacturing. Therefore, this study proposes an integrated forming and curing process for semicured FMLs using a solid granule medium (SGM), with the aim of achieving high-quality forming while minimizing material damage. A refined finite element model incorporating the SGM, aluminum alloy layer, glass-fiber prepreg, and interlayer interface was developed to investigate the coupled effects of flexible SGM forming and the semicured material state. The effects of key process parameters, including the blank-holder gap and specimen size, on the forming quality of deep-drawn components were systematically analyzed. Compared with the conventional rigid mold forming process, SGM forming increased the deep-drawing height by approximately 22% and effectively reduced stress concentration in the die-fillet region. Owing to the viscous resin flow and compensating interlayer slip, the forming limit of the semicured laminate was approximately 16.8% higher than that of the fully cured laminate. After SGM forming, the components were cured under pressure during a controlled heating process. The cured FMLs exhibited strong interlayer bonding and clear, intact interfaces, with no interfacial defects observed. These results demonstrate that the proposed SGM forming and curing process can improve the formability of FMLs, reduce forming-induced damage, and simplify the production of complex-shaped components.

Cite this article

DU, Bing . Integrated Forming and Curing of Semi-Cured Fiber Metal Laminates Using a Solid Granule Medium[J]. Acta Metall Sin, 0 : 0 . DOI: 10.11900/0412.1961.2025.00397

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