Investigating the Structural Strength of Al5052-PVC-Al5052 Sandwich Sheets Using Lap-Shear and T-Peel Testing

Chinmaya Prasad Padhy; P. Praveen Kumar Reddy

doi:10.15282/ijame.22.2.2025.1.0938

Authors

Chinmaya Prasad Padhy Faculty of Department of Mechanical Engineering, School of Technology, GITAM Deemed to be University, Hyderabad, India
P. Praveen Kumar Reddy Faculty of Department of Mechanical Engineering, School of Technology, GITAM Deemed to be University, Hyderabad, India

DOI:

https://doi.org/10.15282/ijame.22.2.2025.1.0938

Keywords:

Al5052-PVC-Al5052, Composite sheets, Structural strength, Failure analysis, Lap shear test

Abstract

The sheet metal forming process stands as a cornerstone in metal forming operations, boasting broad applications across diverse sectors such as automotive, aerospace, and marine industries. With a history spanning over four decades, it remains an irreplaceable method. However, the ongoing emphasis on optimizing strength-to-weight ratios has spurred researchers to explore alternative approaches. Among these, the fabrication of sandwich sheets has emerged as a promising concept, maintaining the desired balance between strength and weight. The present work aimed to fabricate and test Al5052 base sheet material (Lap shear test) and Al5052-PVC-Al5052 sandwich sheets (Lap shear and T-Peel Tests) in various rolling direction combinations. For Lap shear test three different types of test samples were made by riveting such as base material (1mm thickness), base material with PVC 0.5 and 1mm thickness in lap area. These lap shear test specimens were made in different rolling direction combinations, for instance, with base sheet (0°-0°,45°-45°, 90°-90°, 0°-45°, 90°-45° and 0°-90°).T-Peel test performed with the sandwich material with PVC 0.5mm thickness in different rolling directions. Based on the study, the primary outcomes were identified in terms of the maximum shear strength and pulling force. Additionally, the failure mechanisms were observed, particularly in the rivet zone of both the base and sandwich sheets. Maximum Lap shear strength shown for the base is 2.344 kN (90°-45°), PVC 0.5mm thickness is 2.674 kN (45°-PVC-45°), and PVC 1mm thickness is 2.460 kN (90°-PVC-45°). The maximum peeling force in T-Peel test with PVC 0.5mm thickness is 71.1 kN (45°-PVC-45°). The results indicate a significant enhancement in both maximum shear strength and peeling (pulling force) due to the presence of PVC.

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