Method for Analyzing the Effect of Thermal Residual Stress in Fiber Metal Laminates during ELS Test

LI Dan; TIAN Yuanhao; YI Li; DING Zhaohu; QIN Xufeng; ZHOU Jie; NING Huiming

doi:10.19554/j.cnki.1001-3563.2026.19.024

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Packaging Engineering ›› 2026, Vol. 47 ›› Issue (19) : 237-246. DOI: 10.19554/j.cnki.1001-3563.2026.19.024

Equipment Protection

Method for Analyzing the Effect of Thermal Residual Stress in Fiber Metal Laminates during ELS Test

LI Dan¹, TIAN Yuanhao^2,*, YI Li², DING Zhaohu¹, QIN Xufeng², ZHOU Jie², NING Huiming¹

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Abstract

To address the bias in the measured Mode II interlaminar fracture toughness of asymmetric fiber-metal laminate (FML) specimens caused by residual thermal stresses during end-loaded split (ELS) test, the work aims to develop a correction method for the apparent fracture toughness to improve the accuracy of heterogeneous-interface characterization and the reliability of design parameters for delamination resistance, providing theoretical support for controlling delamination damage, maintaining structural integrity, and designing damage-tolerant FML components for advanced protective equipment subjected to impact, penetration, and blast loading. Based on the characteristics of the hybrid interfaces and asymmetric laminate configurations of FMLs, the effect of residual thermal stresses on ELS test results was analyzed, and a theoretical correction method for the apparent fracture toughness was proposed. Its effectiveness was validated through ELS tests conducted at different temperatures and finite element simulations. For the interfacial Mode II fracture toughness of CFRP/aluminum-alloy FMLs during stable interlaminar crack propagation at the same temperature, the maximum difference between the uncorrected mean apparent fracture toughness values was approximately 1 354 J/m², whereas the maximum difference decreased to approximately 244 J/m² after correction, with a marked reduction in the scatter of the test results. These findings demonstrate that residual thermal stresses significantly affect the apparent fracture toughness obtained from ELS tests on asymmetric FML specimens. The proposed correction method effectively reduces the evaluation error induced by thermal stresses, improves the accuracy of interfacial Mode II fracture toughness measurements, and provides more reliable parameters for the delamination-resistant design of FML structures.

Key words

fibre-metal laminates / fracture toughness / Mode II delamination propagation / thermal residual stress / cohesive zone model

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LI Dan, TIAN Yuanhao, YI Li, DING Zhaohu, QIN Xufeng, ZHOU Jie, NING Huiming. Method for Analyzing the Effect of Thermal Residual Stress in Fiber Metal Laminates during ELS Test[J]. Packaging Engineering. 2026, 47(19): 237-246 https://doi.org/10.19554/j.cnki.1001-3563.2026.19.024

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