Hybrid titanium composite laminates (HTCLs) combine the benefits of thin titanium sheets and fiber-reinforced polymer (FRP) composite laminates to design high performance light-weight materials with optimized impact resistance, fracture toughness, durability, and/or thermal performance. This paper starts with a detailed review of typical failure modes observed in HTCLs. The critical manufacturing process of thin grade II titanium sheets combined with HexPly G947/M18 carbon fiber-reinforced polymer laminates is described in detail. This includes the evaluation of titanium surface preparation techniques, which guarantee good adhesive bonding. A systematic experimental study of different HTCL configurations under tensile loading confirms that the major failure modes are debonding between the titanium sheet and the FRP laminate, matrix cracking in the 90 deg plies of the FRP laminate and interlaminar delamination. The results show that HTCLs made from woven carbon FRP plies show higher ultimate strengths and strain at breaks than HTCLs containing a cross-ply composite core made from unidirectional (UD) prepreg.

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