A State-of-the-Art Review on Advanced Joining Processes for Metal-Composite and Metal-Polymer Hybrid Structures

Abstract

Multi-materials of metal-polymer and metal-composite hybrid structures (MMHSs) are highly demanded in several fields including land, air and sea transportation, infrastructure construction, and healthcare. The adoption of MMHSs in transportation industries represents a pivotal opportunity to reduce the product’s weight without compromising structural performance. This enables a dramatic reduction in fuel consumption for vehicles driven by internal combustion engines as well as an increase in fuel efficiency for electric vehicles. The main challenge for manufacturing MMHSs lies in the lack of robust joining solutions. Conventional joining processes, e.g., mechanical fastening and adhesive bonding involve several issues. Several emerging technologies have been developed for MMHSs’ manufacturing. Different from recently published review articles where the focus is only on specific categories of joining processes, this review is aimed at providing a broader and systematic view of the emerging opportunities for hybrid thin-walled structure manufacturing. The present review paper discusses the main limitations of conventional joining processes and describes the joining mechanisms, the main differences, advantages, and limitations of new joining processes. Three reference clusters were identified: fast mechanical joining processes, thermomechanical interlocking processes, and thermomechanical joining processes. This new classification is aimed at providing a compass to better orient within the broad horizon of new joining processes for MMHSs with an outlook for future trends.

Deposition of Biocompatible Polymers by 3D Printing (FDM) on Titanium Alloy

“…Problem occur during the forming process of such hybrids, because both materials exhibit completely different mechanical properties [44,45]. The formation of such joints is based mainly on the mechanical "hooking" of metal elements in polymers; however, a method based on the formation of adhesive joints using increased temperature and pressure is also used [46][47][48][49][50]. There are proposals to use 3D FDM printing to create metal-polymer joints, although they are based on 3D printing by applying polymers to polymers, thereby creating a rivet that holds the metal part [51].…”

Tests and Numerical Study of Single-Lap Thermoplastic Composite Joints Bolted by Countersunk

“…Owing to their superior features, such as high specific strength and stiffness, high specific moduli, damage tolerance, and environmental resilience, carbon-fiber-reinforced thermoplastic (CFRTP) composites have been widely used in the aerospace industry [ 1 , 2 , 3 , 4 , 5 ]. Composite components are divided into numerous parts as per the requirements of structural design, manufacture, and maintenance of composites, as well as the limitations of the integrity molding technology.…”

Experimental investigation of Al5052‐H32/PETG hybrid clinched joints

“…With the persistent innovation of various automotive lightweight technologies and the continuous emergence of various new materials, body structure optimization, manufacturing process improvement, and lightweight material application have become the frequently used approaches of automotive lightweight design in recent decades. [1][2][3][4][5] In terms of body structure optimization, four relatively perfect optimization methods have been formed with in-depth research in the automotive manufacturing field, such as topology optimization, size optimization, shape optimization, and topography optimization. In addition, in terms of manufacturing process improvement, some novel connection techniques have also been proposed in recent decades, including adhesive bonding, self-piercing riveting, mechanical clinching, laser welding, friction stir clinching, etc.…”