碳纖維強化聚合物具有強度高質量輕的特性，而鋁合金則是質量輕且具良好的可加工性，兩者常於輕量化構造設計中廣泛合併應用，其中薄層碳纖維預浸料通常只有標準層預浸料之30%~50%厚，且薄層設計的碳纖維層壓板可更有效抵抗受力後應力集中所造成的致災性損壞，在追求輕量化目的下更確保其強度，具比標準層預浸料更靈活的鋪層設計應用。因此本研究將標準型[0°/90°]8S碳纖維層壓板之90˚層混合引入單向薄型預浸料(Unidirectional Thin-ply Prepreg)，以檢視混合型[0°/90°x2]8S碳纖維層壓板在單向纖維方向垂直於軸向力之下，90˚層對比標準型薄化後之影響；並進一步鍛壓鉚接開孔碳纖維層壓板及3D列印鋁合金部件為Single-lap輕結構件，為分析比較標準型與混合型碳纖維層壓板之承載能力(Load-bearing)及其破壞行為。首先，對此兩款碳纖維層壓板進行開孔拉伸(Open-hole Tension)試驗，在都呈現偽延性(Pseudo-ductility)特徵下得混合型碳纖維層壓板在偽延性的表現上優於標準型；且兩者的開孔敏感性(Notch Sensitivity)皆不高，即對開孔損壞的表現不敏感，甚或是混合不同厚度預浸料所製備之疊層板亦不受影響；此外，藉由各階段性的拉伸，探討開孔拉伸時碳纖維層間的損壞演化，釐清標準型碳纖維層壓板在承受單軸開孔拉伸時將橫向層(90˚層)薄化所改變之破壞抵抗能力。另一方面，有限元素輔助分析接合製程以建置鉚接開孔碳纖維層壓板於3D列印鋁合金零件上之實驗，由Single-lap構件發現鋁合金於塑性成形接合過程中產生一定程度的側擠進而導致纖維層產生波浪紋，量化側擠造成的擴孔尺寸，與原鉚接頭直徑之設計值定義為干涉量，結果闡明混合型碳纖維層壓板在搭接過程中具有吸收鍛壓力之優勢。最後，將鉚接後之Single-lap構件進行關鍵階段之承載拉伸試驗，實驗結果得知混合型之偽延性較標準型高，而真實承載應力的展現亦優於標準型2.61%；綜合微觀組織的破壞裂痕形貌亦證明混合型碳纖維層壓板在吸收能量能力及偽延性特質較佳的情況下，提升整體承載行為之表現。

The way to widely used in lightweight structural design by applying carbon fiber reinforced polymer (CFRP) with its high strength-to-weight ratio and good processability aluminum light alloy. Thin-ply carbon fiber prepreg is usually only 30%~50% thickness than standard prepreg, and a CFRP laminate with thin-ply design performing effectively resist catastrophic damage caused by stress concentration after being subjected load-bearing, further to pursue the lightweight structure as well as to ensure its strength, thus it has more flexible to lay-up design and application than standard one. In this study, the 90˚-layer of standard [0°/90°]8S CFRP laminate was designed with unidirectional (UD) thin-ply prepreg, the hybrid [0°/90°x2]8S CFRP laminate for investigating the influence of 90°-layer thinning on mechanical properties of standard CFRP laminate under the state of UD thin-ply prepreg perpendicular to the axial force. Further, the open-hole CFRP laminate was riveted to 3D-printed aluminum alloy component through joining by forming process. The Single-lap lightweight structures were fabricated for testing the load-bearing capacity and failure behavior between standard and hybrid CFRP laminates. Initially, the open-hole tension tests were carried out on the standard and hybrid CFRP laminates, and the hybrid CFRP laminate held the pseudo-ductility superior to the standard one. Also, the notch sensitivities of both types were examined, in which the steady sensitivity to the damage response even the hybrid CFRP laminate prepared by mixing different thicknesses of prepregs was performed. In addition, the damage evolution for describing the damage resistance of standard CFRP laminate with thinning the transverse layer (90˚-layer) while subjected to uniaxial open-hole tension was clarified as well. On the other hand, finite element-assisted analysis of the joining process to construct riveting of additively manufactured aluminum alloy part to perforated CFRP laminate was presented. Joint section of riveted Single-lap was cut for quantifying interference after the joining process, which was defined hole expansion by lateral interference / original diameter, besides, the wave characteristics were observed in layers of CFRP laminate. Subsequently, the hybrid CFRP laminate performed better energy absorption from forging pressure during the joining process was elucidated. Finally, the riveted Single-lap systems were subjected to a load-bearing tensile tests at various critical stages. The experimental results shown that the pseudo-ductility of the hybrid type contributed better than that of the standard type, and the performance of the true load-bearing stress offered 2.61% higher than that of the standard type overall. Hence, the damage (crack morphology) of the comprehensive microstructure evolution, the hybrid CFRP laminate possessed the advantages of energy absorption capacity and pseudo-ductility for enhancing the total load-bearing behavior compared to the standard one.

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