Incremental sheet forming of tailored hybrid metal/polymer/metal sandwich composites for engineering and biomedical applications
Final Report Abstract
Metal/polymer/metal (MPM) sandwich composites present strong potential for aerospace and automotive applications due to their low weight and favorable mechanical performance. Their customizability also makes them attractive for biomedical uses—for example, in skull reconstruction—where tailored stiffness and improved comfort are critical. Additionally, MPMs offer opportunities for tuning acoustic, thermal, and electrical properties for specialized functions. This project focused on establishing a fundamental understanding of the forming behavior and failure mechanisms of steel-based MPM sheets under various geometrical and process conditions using Incremental Sheet Forming (ISF). Through a combination of experimental analysis and FEM simulations, key process parameters were identified, and a validated modeling approach was developed. This foundation enables the design of tailored process windows to produce defect-free, dimensionally accurate MPM components. The results serve as a valuable starting point for future research and knowledge transfer, particularly in industries requiring lightweight, high-performance structures with complex geometries. The validated strategies from this study can also support scaling up to more advanced MPM systems or the development of application-specific forming technologies.
Publications
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Incremental sheet forming of steel/polymer/steel sandwich composites. Journal of Materials Research and Technology, 13, 417-430.
Harhash, Mohamed & Palkowski, Heinz
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Incremental Sheet Forming on Tailored Hybrid Steel/Polymer/Steel Sandwich Materials; Formability and Residual Stress Investigation. JOM, 77(10), 7505-7518.
Khani, Somayeh; Harhash, Mohamed; Palkowski, Heinz & Buhl, Johannes
