a b s t r a c tA novel metal-composite joining technology is presented. Hybrid penetrative reinforcement (HYPER) uses small pins, protruding from the metallic part, to form an integrated assembly with high toughness. Different pin geometries and surface treatments are mechanically tested and compared. An ultrasonic, non-destructive inspection method is used to determine the failure modes. It is shown that the pins delay the initiation of failure, slow the propagation of damage and increase the ultimate strength by 6.5 times compared to an unpinned benchmark joint. The mean elongation at maximum load can be increased by over 400% and the energy absorbed can be more than 80 times higher, with reinforcement. Surface ''nano-structuring'' is also found to improve titanium-composite adhesion strength and consistency. Subsequently, a 25% higher load is required to initiate failure.

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