A mechanical interlocking joint between sheet metal and carbon fibre reinforced polymers through punching

Abstract The joint between different lightweight materials plays a significant role in multi-material design of structural components for the automotive industry, aiming to reduce vehicle’s weight without compromising performance or safety. Yet, conventional mechanical joining technologies metals and Carbon Fibre Reinforced Polymers (CFRP) result either hole being drilled composite material, leading damages which load bearing capacity, part increased due incorporation fasteners. At same time, alternative methodologies involve complex costly processing, hindering their industrial application. This work presents new, simple, cost-efficient non-weight penalizing technology metal sheet fibre reinforced polymer prepregs consisting single-step punching process. In this process, metallic is completely perforated, while prepreg not. punch pushes carbon fibres through hole, with no, minimal breakage, generating interlock. shear strength absorbed energy co-cured increase interlocking joint.