Skip to main content

DEVELOPMENT OF MUTILAYER STRUCTURAL THIN METAL SHEETS WITH CONVENTIONAL WORKABILLITY AND SUPERIOR OVERALL PERFORMANCE

Objective

Laminates for technical applications manufactured by means of the Cellular / Stratified method (C&S - patent pending), are well matched to the requirement of large/medium entreprises involved in mass production. The relevant reduction in weight obtained with C&S laminates, is coupled with a noticeable increase in the thermoacoustic insulation, at a fabrication cost, which is relatively low. Base materials for such a laminate typology can be thin layers of metallic alloys, as well as films of various organic materials, from wood to paper, up to plastics.
Large and medium mass production entreprises are continuously looking for innovative laminates to increase competitiveness of their products, with respect to non-European markets.

Laminates manufactured with the Cellular/Stratified (C&S) system also satisfy the design requirements for a reduction weight up to 1/2 - 1/3 with respect to traditional bulk laminates with equal flexural-torsional stiffness and the possibility to use processing techniques already involved for conventional laminates (cutting, bending, deep drawing). Laminates with the C&S system should have a fabrication cost increase limited to a factor 1.1-1.5 with respect to traditional laminates.

The basic principle for the manufacturing of C&S laminates involves coupling of a pair of thin external layers with an inner honeycomb structure by means of strong welding/glueing. The honeycomb is realised by a double side crossed corrugation at a fine pitch, obtained from a plain sheet of deformable material of suitable thickness.
The basic manufacturing principle may be applied to a wide series of different materials.

From the existing patents and structural calculations, the project focused on the development of the production technology of the laminate, up to the construction of significant samples in order to allow testing and comparison with FEA predictions. The project aimed to define the following steps: production of bumped sheet, joining technologies (from laser welding to ultrasonic soldering to resistance spot welding), deformation controls and related sensors, adaptation of rolling technology. By the end of the project, samples of C&S laminated were available for testing and qualification procedures together with an assessment of the technical/economic convenience with respect to the various potential applications.

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

Istituto per le Ricerche di Tecnologia Meccanica e per l'Automazione SpA
Address
Regione Lime
10080 Vico Canavese Torino
Italy

Participants (4)

CENTRO RICERCHE FIAT S.C.P.A.
Italy
Address
Strada Torino 50
10043 Orbassano
Delta Di Amidei Dario & C. Sas
Italy
SIEMENS AG ZT MF 4
Germany
TECHNICAL UNIVERSITY OF DENMARK
Denmark