Joining of CFRT/Steel Hybrid Parts via Direct Pressing of Cold Formed Non-Rotational Symmetric Pin Structures

In this study, quasi-unidirectional continuous fiber reinforced thermoplastics (CFRTs) are joined with metal sheets via cold formed cylindrical, elliptical and polygonal pin structures which are directly pressed into the CFRT component after local infrared heating. In comparison to already available studies, the unique novelty is the use of non-rotational symmetric pin structures for the CFRT/metal hybrid joining. Thus, a variation in the fiber orientation in the CFRT component as well as a variation in the non-rotational symmetric pins’ orientation in relation to the sample orientation is conducted. The created samples are consequently mechanically tested via single lap shear experiments in a quasi-static state. Finally, the failure behavior of the single lap shear samples is investigated with the help of microscopic images and detailed photographs. In the single lap shear tests, it could be shown that non-rotational symmetric pin structures lead to an increase in maximum testing forces of up to 74% when compared to cylindrical pins. However, when normalized to the pin foot print related joint strength, only one polygonal pin variation showed increased joint strength in comparison to cylindrical pin structures. The investigation of the failure behavior showed two distinct failure modes. The first failure mode was failure of the CFRT component due to an exceedance of the maximum bearing strength of the pin-hole leading to significant damage in the CFRT component. The second failure mode was pin-deflection due to the applied testing load and a subsequent pin extraction from the CFRT component resulting in significantly less visible damage in the CFRT component. Generally, CFRT failure is more likely with a fiber orientation of 0° in relation to the load direction while pin extraction typically occurs with a fiber orientation of 90°. It is assumed that for future investigations, pin structures with an undercutting shape that creates an interlocking joint could counteract the tendency for pin-extraction and consequently lead to increased maximum joint strengths.