Innovative Metal-Composite Joints Based on Combined Production Process

In various fields, such as aerospace and automotive, the necessity to find efficient methods for combining different materials like metals and composites continues to be an important focus of research. This study meticulously explores how additive manufacturing techniques can be utilized to facilitate the union between these two materials and create a novel joining method. More specifically, the investigation centers around the creation of a metal adherent via additive manufacturing, simultaneously co-curing the composite within this freshly developed geometry, aiming to achieve improved resilience under different loading conditions. To achieve this objective, An extensive analysis was conducted using various shapes that may be created using additive manufacturing techniques. The focus was predominantly on assessing the resilience and capability of these geometries to withstand specified loads during tensile loading conditions. As the main experimental component, single lap joints were used, each including two distinct adherents: one made of carefully adjusted metal geometry and the other of Carbon Fibre Reinforced Polymer (CFRP). The primary phase of this investigation involved simulating tensile loading conditions across the entire joint utilizing different geometries, facilitated through the ANSYS Mechanical module. The objective was to gain knowledge about the joints' strengths and make reliable comparisons between them. Following this, the Cohesive Zone Modelling (CZM) method was used to gain a detailed understanding of the load distribution and stress concentrations caused by various geometries. Due to the epoxy matrix's function as an adhesive during the metal and composite adherent's co-curing phase, this technique was thought to be crucial. Therefore, a more thorough analysis using CZM would provide crucial information on how different geometries respond to the given stress, illuminating the potential opportunities for improving joint strength. The results of this thorough analysis showed that the various geometries significantly affected the overall joint strength. It was discovered that generally speaking, the geometries that promoted mechanical locking appeared to lessen the peeling effect, potentially strengthening the adhesion in addition to even improving the general strength properties of the joint. The study also showed that, depending on the precise shape used on the metal adherent, the failure mode of the joint might be modified to some extent. This creates a viable route for increasing the joints' strength and controlling their failure modes, giving the newly created joints some predictability and dependability. In conclusion, this work aims to add to the body of knowledge already available about the procedures for joining metals and composites, using additive manufacturing methods. The preliminary results suggest the possibility that specific geometries may enhance mechanical locking, which may have a positive impact on joint strength. In order to encourage a deeper examination and a better knowledge of the dynamics involved in the joining of metals and composites, this research opens up options for more extensive future studies.