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• Comparative analysis of processing conditions and characterization of dissimilar metal–thermoplastic composite Joints

  S. Dasilva, Á. Rodríguez, P. Rodríguez Alonso, B. Gomes, F. Ares-Blanco, C. Blanco Veiga, S. Trillo Lago

  Materiales Compuestos (2026). Vol. 09 - Comunicaciones MatComp25 (2025), (Núm. 5 - Reciclaje y Sostenibilidad - Aplicaciones), 39

  
  

  Abstract

  The demand for lightweight and high-strength materials across various industries has driven research into hybrid structures that combine the mechanical advantages of metals with the low weight and strength of carbon fiber-reinforced composites. The use of thermoplastic composites additionally enables disassembly and reuse at the end of the service life. Furthermore, the metal-composite joining process and the thermoplastic CFRP processing could potentially be achieved in a single step, resulting in reduced manufacturing cycle times and overall higher productivity. However, several challenges must be addressed, such as differences in the coefficients of thermal expansion, the influence of the composite processing parameters on the metallic material and its surface treatment, and the potential formation of galvanic couples. This study investigates different manufacturing methods for dissimilar or multi-material joints: automated fiber placement (AFP) and thermoforming. A comparison is presented based on the manufacturing parameters, which were adjusted to maximize joint strength for each process.A cross-sectional optical microscopy analysis was carried out to evaluate the joint interface and the interaction between the surface treatment and the thermoplastic resin matrix layer, which is responsible for the adhesive bond between both components. In addition, mechanical testing was conducted to assess the influence of processing parameters, establishing a joint design route for optimized performance evaluation. The conclusions demonstrate that the polymer layer at the interface plays a key role in compensating for differences in thermal expansion coefficients, leading to enhanced mechanical performance of the joint. The advantages and limitations of each manufacturing method are discussed in this work.

  Abstract
  The demand for lightweight and high-strength materials across various industries has driven research into hybrid structures that combine the mechanical advantages of metals [...]

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