Thermal residual stresses in thermoplastic CFRP-steel laminates: Modification and influence on fatigue life

Thermal residual stresses (TRS) in hybrid materials and structures occur by the mismatch of thermal expansion of different materials. Especially when combining metals with carbon fiber reinforced plastics (CFRP), a significant level of internal stresses can be reached. High processing temperatures and high stiffness of the constituents are also responsible for high stress levels. Laminates of thermoplastic CFRP (unidirectional carbon fiber reinforced polyamide 6) and stainless steel foils are a suitable material system to examine the TRS in detail. Since TRSs in the steel fraction are of tensile nature, these superpose to externally applied loads, resulting in higher efforts for the material and thus reduced lifetimes under cyclic fatigue loading. Therefore, a reduction of TRS is desired. Two methods for TRS reduction were applied, and its influence on fatigue lifetime was investigated. Firstly, specimens were stretched by a preloading to reduce TRS by yielding of the metal. Secondly, non-symmetric laminates were gradually cooled down after consolidation to compensate TRS formation by non-symmetric shrinkage. While preloading of materials and structures is known for TRS modification, the gradually cooling is not established, yet. Both modification principles were numerically investigated before experimental validation. A significant increase of lifetime was reached by TRS reduction.