Co-authors​ :

 Mohammadali RASTAK (CANADA), Suong V. HOA (CANADA), Daniel ROSCA  

Composite materials are gaining popularity owing to their exceptional mechanical properties, such as strength and resistance to fatigue, and their lightweight nature. However, due to their inherent brittleness, they are susceptible to sudden load failure. Conversely, metals such as aluminum demonstrate ductility, which captivates interest owing to their tendency to exhibit a smoother fracture mechanism. Nevertheless, metals usually are not lightweight. Moreover, while metals typically demonstrate remarkable strength, their strength cannot be compared to that demonstrated by composite materials. Hybrid materials, which combine the ductility of aluminum with the stiffness and strength of composite materials like carbon, are increasingly being adopted as an alternative to address the aforementioned challenges associated with both materials. This methodology provides enhanced energy absorption, impact resistance, and overall performance. The helicopter landing gear is a compelling application for these hybrid composite/metal structures, as they exhibit superior performance over conventional aluminum tubes while simultaneously reducing their overall weight. Due to the fact that these structures are subjected to bending loads, flexural rigidity is one of the important parameters and it needs to be considered. Furthermore, it is essential to examine the bending response of hybrid aluminum/thermoplastic composite tubes in order to gain a better understanding of their overall performance when compared to single aluminum tubes that are frequently used in landing gear components. To streamline the study, it is viable to consider the region experiencing pure bending conditions in an actual landing gear as a straight tube and conduct the study accordingly. To make such a hybrid aluminum/thermoplastic composite, Automated Fiber Placement (AFP) can be employed to wrap the Carbon-PEEK, as the thermoplastic composite part, around an aluminum tube. AFP technology ensures precision during manufacturing, minimizing errors. This paper provides the manufacturing process for hybrid aluminum/Carbon-PEEK tubes using AFP technology, along with experimental pure bending tests. To ensure a pure bending condition, four-point bending tests were conducted. The results are compared with the solely aluminum tube to evaluate their respective performances. The results indicate the feasibility of incorporating composite material into an aluminum tube to enhance both strength and stiffness. Furthermore, following tube failure, there is a secondary resistance in the tube that enables continued support of the load at a diminished level. This attribute is crucial in preventing abrupt shocks in the event of a load dropping to zero after reaching maximum capacity.