Forming induced interface structures for manufacturing hybrid metal composites

The performance of hybrid metal composite parts strongly depends on the properties of the mechanical interface between the two components as well as on the deformation behavior. A combination of different joining mechanisms (e.g. adhesive bonding, mechanical form-fit) offers enhanced interface performance. This paper shows a novel interface concept based on form-fit elements induced by forming. Compared to other joining methods, the forming induced interface structure provides improved strength as well as energy absorption. Shear tests show an increase of up to 40% in shear strength and up to 78% in fracture energy compared to non-structured adhesive bondings.