Advances in Mechanical Joining Techniques for Metal–Composite Hybrid Structures
A Mini Review
DOI:
https://doi.org/10.57159/jcmm.4.2.25194Keywords:
Composite–metal Joints, Additive Manufacturing, Fiber Reinforcement, Mechanical Joining, Hybrid StructuresAbstract
The integration of fiber-reinforced polymer (FRP) composites with metal components in aerospace and automotive structures presents significant mechanical and design challenges, especially when conventional bolted joints induce fiber disruption and delamination. This mini review provides a comprehensive evaluation of emerging mechanical joining techniques developed to address these limitations. Key approaches discussed include self-piercing and friction riveting, mechanical clinching, non-adhesive form-locked joints, pin and loop joining, and recent advances enabled by additive manufacturing technologies. Each technique is examined in terms of joining mechanism, material compatibility, process constraints, and structural performance. Additionally, the role of nanofiber reinforcement in enhancing the interlaminar toughness of composite laminates is explored, emphasizing its effect on joint durability and resistance to failure. Comparative insights are offered on joint reversibility, complexity, galvanic behavior, and suitability for thermoplastic and thermoset matrices. Despite notable progress, most advanced joining strategies still face practical hurdles related to manufacturability, scalability, and long-term environmental durability. The review highlights that minimizing fiber damage often entails increased process complexity and cost. Therefore, future directions should focus on developing standardized evaluation protocols, optimizing additive manufacturing for multi-material interfaces, and integrating nanoscale reinforcements to achieve structurally robust, lightweight, and corrosion-resistant hybrid assemblies. This synthesis serves as a technical guide for engineers and researchers aiming to design next-generation composite–metal joints for high-performance applications.
References
I. Shyha, S. Soo, D. Aspinwall, and S. Bradley, “Effect of laminate configuration and feed rate on cutting performance when drilling holes in carbon fibre reinforced plastic composites,” Journal of Materials Processing Technology, vol. 210, no. 8, pp. 1023–1034, 2010.
T. Lim, B. Kim, and D. Lee, “Fatigue characteristics of the bolted joints for unidirectional composite laminates,” Composite Structures, vol. 72, no. 1, pp. 58–68, 2006.
R. Li, D. Kelly, and A. Crosky, “Strength improvement by fibre steering around a pin loaded hole,” Composite Structures, vol. 57, no. 1–4, pp. 377–383, 2002.
A. Pramanik, A. K. Basak, Y. Dong, P. K. Sarker, M. S. Uddin, G. Littlefair, S. Dixit, and S. Chattopadhyaya, “Joining of carbon fibre reinforced polymer (CFRP) composites and aluminium alloys - a review,” Composites Part A: Applied Science and Manufacturing, vol. 101, pp. 1–29, 2017.
A. Galińska, “Mechanical joining of fibre reinforced polymer composites to metals - a review. Part I: Bolted joining,” Polymers, vol. 12, no. 10, p. 2252, 2020.
Z. Dawei, Z. Qi, F. Xiaoguang, and Z. Shengdun, “Review on joining process of carbon fiber-reinforced polymer and metal: methods and joining process,” Rare Metal Materials and Engineering, vol. 47, no. 12, pp. 3686–3696, 2018.
S. Amancio-Filho and J. Dos Santos, “Joining of polymers and polymer–metal hybrid structures: recent developments and trends,” Polymer Engineering & Science, vol. 49, no. 8, pp. 1461–1476, 2009.
P. Kah, R. Suoranta, J. Martikainen, and C. Magnus, “Techniques for joining dissimilar materials: Metals and polymers,” Reviews on Advanced Materials Science, vol. 36, no. 2, 2014.
G. Di Franco, L. Fratini, A. Pasta, and V. F. Ruisi, “On the self-piercing riveting of aluminium blanks and carbon fibre composite panels,” International Journal of Material Forming, vol. 6, no. 1, pp. 137–144, 2013.
X. Cheng, S. Wang, J. Zhang, W. Huang, Y. Cheng, and J. Zhang, “Effect of damage on failure mode of multi-bolt composite joints using failure envelope method,” Composite Structures, vol. 160, pp. 8–15, 2017.
A. Ibrahim, Experimental Assessment and Computational Modeling of Adhesive, Self Piercing Rivets (SPR), and Hybrid (Adhesive-SPR) Joints: Enhancing Joint Performance for Aluminum Sheet Material, Ph.D. dissertation, University of Waterloo, 2023.
A. K. Basak, D. S. Bajwa, and A. Pramanik, “Fatigue behaviour of mechanical joints: A review,” Metals, vol. 15, no. 1, p. 25, 2024.
G. Di Franco, L. Fratini, and A. Pasta, “Influence of the distance between rivets in self-piercing riveting bonded joints made of carbon fiber panels and AA2024 blanks,” Materials & Design, vol. 35, pp. 342–349, 2012.
N. R. J. Hynes, N. Vignesh, and P. S. Velu, “Low-speed friction riveting: A new method for joining polymer/metal hybrid structures for aerospace applications,” Journal of the Brazilian Society of Mechanical Sciences and Engineering, vol. 42, no. 8, p. 434, 2020.
Y.-Y. Zhang, Z. Sun, P. Huang, Y.-Q. Li, Q. Chen, and S.-Y. Fu, “Experimental and numerical investigations of wear behaviors of short-carbon-fiber reinforced polyetherimide composite,” Composite Structures, vol. 270, p. 114057, 2021.
J. Min, S. Park, and Y. Kim, “Friction stir blind riveting of CFRP to aluminum: Feasibility and mechanical performance,” Materials, vol. 12, no. 1, p. 120, 2019.
H. Shahmiri, M. Movahedi, and A. Kokabi, “Friction stir lap joining of aluminium alloy to polypropylene sheets,” Science and Technology of Welding and Joining, vol. 22, no. 2, pp. 120–126, 2017.
P.-C. Lin, J.-W. Lin, and G.-X. Li, “Clinching process for aluminum alloy and carbon fiber-reinforced thermoplastic sheets,” The International Journal of Advanced Manufacturing Technology, vol. 97, no. 1, pp. 529–541, 2018.
C. Worrall, E. Kellar, and C. Vacogne, “Joining of fibre-reinforced polymer composites: A good practice guide,” Composites UK Ltd, pp. 1–77, 2020.
A. T. Nguyen, M. Brandt, S. Feih, and A. C. Orifici, “Pin pull-out behaviour for hybrid metal-composite joints with integrated reinforcements,” Composite Structures, vol. 155, pp. 160–172, 2016.
L. Raimondi, L. Tomesani, and A. Zucchelli, “Enhancing the robustness of hybrid metal-composite connections through 3D printed micro penetrative anchors,” Applied Composite Materials, vol. 31, no. 4, pp. 1275–1293, 2024.
S. Ucsnik, M. Scheerer, S. Zaremba, and D. Pahr, “Experimental investigation of a novel hybrid metal–composite joining technology,” Composites Part A: Applied Science and Manufacturing, vol. 41, no. 3, pp. 369–374, 2010.
V. Wottschel and F. Vollertsen, “CFRP-aluminium structures realized by laser beam joining process,” Advanced Materials Research, vol. 907, pp. 89–96, 2014.
S. Rajendran, G. Palani, A. Kanakaraj, V. Shanmugam, A. Veerasimman, S. Gądek, K. Korniejenko, and U. Marimuthu, “Metal and polymer based composites manufactured using additive manufacturing - a brief review,” Polymers, vol. 15, no. 11, p. 2564, 2023.
S. Razzaq, Z. Pan, H. Li, S. Ringer, and X. Liao, “Joining dissimilar metals by additive manufacturing: A review,” Journal of Materials Research and Technology, vol. 31, pp. 2820–2845, 2024.
P. N. Bellamkonda, M. Dwivedy, and R. Addanki, “Cold metal transfer technology - a review of recent research developments,” Results in Engineering, vol. 23, p. 102423, 2024.
C. Schneider-Bröskamp, M. Schnall, A. Birgmann, and S. Ucsnik, “Mechanical and microstructural characterization of aluminium micro-pins realized by cold metal transfer,” The International Journal of Advanced Manufacturing Technology, vol. 127, no. 7, pp. 3255–3267, 2023.
F. Lambiase, S. I. Scipioni, C.-J. Lee, D.-C. Ko, and F. Liu, “A state-of-the-art review on advanced joining processes for metal-composite and metal-polymer hybrid structures,” Materials, vol. 14, no. 8, p. 1890, 2021.
U. A. Shakil, S. B. A. Hassan, M. Y. Yahya, and S. Nauman, “Mechanical properties of electrospun nanofiber reinforced/interleaved epoxy matrix composites - a review,” Composites Part B: Engineering, vol. 197, p. 108040, 2020.
P. Santos, A. P. Silva, and P. N. Reis, “The effect of carbon nanofibers on the mechanical performance of epoxy-based composites: a review,” Polymers, vol. 16, no. 15, p. 2152, 2024.
B. Mahato, S. V. Lomov, A. Shiverskii, M. Owais, and S. G. Abaimov, “A review of electrospun nanofiber interleaves for interlaminar toughening of composite laminates,” Polymers, vol. 15, no. 6, p. 1380, 2023.
Downloads
Published
How to Cite
License
Copyright (c) 2025 Journal of Computers, Mechanical and Management
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
The Journal of Computers, Mechanical and Management applies the CC Attribution- Non-Commercial 4.0 International License to its published articles. While retaining copyright ownership of the content, the journal permits activities such as downloading, reusing, reprinting, modifying, distributing, and copying of the articles, as long as the original authors and source are appropriately cited. Proper attribution is ensured by citing the original publication.
The journal is licensed under an 