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Keywords:

  • Aluminum;
  • Automotive;
  • Sandwich structures

This paper describes the development of thin all-metal sandwich sheets. Sandwich sheets are used in various engineering applications, but the lack of formability and weldability has prevented their wide spread use in the automotive industry. The failure modes of state-of-the-art sandwich sheets in forming operations have been analyzed in detail. Based on theoretical analysis, a formable prototype sandwich sheets has been designed. A draw bending experiment has been performed to demonstrate the formability of this prototype sheet.