Novel Metallic Composites Created by Continuous Plasma Cladding

A novel reel-to-reel bonding technology will be presented which enables the use of commercially available metals to create a new class of 3-layer, hollow cored, lightweight composites.  The technology uses vacuum roll bonding to continuously clad metal skins over a perforated or expanded metal core without the need for secondary adhesives, solders or brazing materials.   With high stiffness skins clad to an ultra-low density core material, strength- and stiffness-to-weight properties of the composite in bending exceed those available with conventional monometals.  Design considerations and alloy options will be described including materials and clad geometry selections.   Analytical and modelling analyses of various clad configurations will be presented and compared with experimental results for mechanical properties.   An overview then extends to new configurations and applications examples for future consideration.