Abstract:
Drilling is an essential process in the construction of aircraft panels made from composite/metal stack materials, and it has
a considerable impact on the performance of the aircraft during flight and its overall lifespan. Among CFRP/Al/Ti, CFRP/
Ti, and CFRP/Al stacks, CFRP/Al panels are widely used in the aviation industry. This paper examines in detail the develop
ments made in the drilling of stacks made of carbon fiber reinforced polymer (CFRP) and aluminum (Al), with the goal of
determining how different machining parameters affect the quality of the holes. The primary requirements for aircraft com
ponents are to attain a low level of hole surface roughness, minimize burr heights, reduce the diameter difference in stack-up,
and minimize delamination. The subject matter encompasses a wide range of tool shapes, materials, drilling parameters, and
innovative methods of cooling and coating, all with the goal of reducing hole damage and improving quality. In addition, the
paper examines several forms of hole damage and presents modern methodologies for their quantification. This review study
aims to develop a reliable standard for achieving accuracy, optimal productivity, and reducing harm in the drilling procedure
of CFRP/Al stacks in aerospace applications. Future works on analysis of bond strength, hardness, and coefficient of friction
of coated drill bits and application of nano fluid-based coolants may further enhance the drilling quality
