Title: Architectural Homogenization and Synergistic Toughening in Double-Double Fiber Metal Laminates

Authors: Jason Moon, Logesh Shanmugam, Jeffery Baur

DOI:

Abstract: Fiber Metal Laminates (FMLs) are emerging as a critical material solution for Advanced Air Mobility (AAM) applications, specifically for battery enclosures requiring a unique balance of lightweighting, crashworthiness, and electromagnetic interference (EMI) shielding. While FMLs offer superior fatigue life and fracture toughness compared to monolithic metals or traditional composites, their fiber architecture determines its mechanical performance. This study introduces a novel manufacturing approach for carbon fiber core FMLs, leveraging a DoubleDouble (DD) fiber architecture to optimize energy dissipation for battery protection. The proposed hybrid composite system addresses the dual requirements of AAM battery housing: the external metal layers provide inherent EMI shielding to protect sensitive avionics from highvoltage systems, while the DD composite core enhances stress redistribution during dynamic impact loadings. To validate this architecture for structural enclosures, performance was characterized through open hole tensile testing compared to baseline laminates. Results demonstrate that the DD FML system yields superior mechanical properties of specific toughness by 58% and strain-to-failure by 84%, surpassing conventional monolithic composite materials. This work presents firsthand practical approach on manufacturing multifunctional FMLs, offering a scalable solution for safe, shielded, and lightweight AAM battery enclosures.

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Conference: SAMPE 2026

Publication Date: 2026/04/27

SKU: 185

Pages: 19

Price: $38.00