Key Takeaways & Executive Findings
- •• Laser surface treatment significantly enhances the long-term reliability of friction lap welded aluminum-polymer composite joints, reducing tensile shear force loss from 91% after 7 days to only 26% after 35 days of accelerated aging. • The improved joint reliability is attributed to micro-mechanical interlocking and favorable stress distribution at the interface, preventing interfacial fracture. • The study addresses a critical gap in understanding thermal degradation effects on metal-polymer hybrid joints, promoting their engineering applications. • The combination of friction lap welding and laser surface treatment offers a promising approach for robust dissimilar material joining in lightweight structures.
Abstract
The effect of thermal degradation on the welded hybrid joints of metal and polymer composites is insufficient, which seriously inhibits the engineering applications of the joints. In this study, robust hybrid joints of metal and polymer composites were fabricated by the combination of friction lap welding (FLW) and laser surface treatment for investigating the effect of accelerated aging on the joint properties. Results showed that the FLW hybrid joints without laser surface treatment exhibited 91% reduction in the tensile shear force (TSF) after 7 days of accelerated aging tests. In contrast, the FLW hybrid joints with suitable laser surface treatment exhibited only 26% reduction in TSF even after 35 days of accelerated aging tests. Fractures of the tensile specimens occurred across the composite plates rather than along the joint interface. The enhanced reliability of the hybrid joints was mainly attributed to (1) the formation of micro-mechanical interlocking between the polymer composites and aluminum alloy plate, and (2) the modification of the stress distribution along the joint interface.
1. Introduction
Fiber-reinforced polymer (FRP) is increasingly used in automotive, aerospace, consumer electronics, and biomedical applications due to its high specific strength, great corrosion resistance, and excellent processability [1]. The automotive industries are seeking to replace more metal components with polymer composite parts, aiming at improving vehicle performance and minimizing vehicle weight. The primary structure of the body-in-white still mainly consists of metals. A reliable joining between metal and polymer composites is in urgent need to take advantage of both the metals and polymer composites for achieving lightweight designs [2].
Great challenges still exist in achieving reliable joining between metals and FRPs due to the significant differences in physical and chemical properties between the two materials [3]. Adhesive bonding [4] and mechanical joining [5] are common joining methods in industries for hybrid structures of metals and polymer composites. Adhesive joints are often produced using unfriendly adhesive agents, which are harmful for the health of operators and consumers. Besides, adhesive joints are susceptible to long-term instability due to the environmental vulnerability of adhesive agents, resulting in the reduction of joint reliability. The adoption of additional parts (such as bolts or rivets) and large overlap areas for mechanical joining leads to a negative effect on lightweighting. In addition, hermetic sealing is difficult to achieve. A combination of mechanical joining and adhesive bonding was often adopted to improve the reliability, hermetic sealing, and corrosion resistance of the joints in the automotive industry, resulting in heavier structures and increased manufacturing costs.
Recently, thermomechanical welding methods, such as friction lap welding (FLW) [6–14], laser welding [15], ultrasonic welding [16], hot press welding [17], injection molding [18], and resistance welding, [19] have been developed to address the issues mentioned above [20]. The welding between the metals and FRP was achieved by applying local heating and compression force during the thermomechanical welding, which promoted the intimate contraction and chemical reaction between the locally melted polymer and the metal at the dissimilar material interface [21].
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Chunyang Jiang, Fengchao Liu, Lihui Wu, Ying Kan, Xianjun Pei, Hao Zhang, Zhen Zhang, Peng Xue, Dingrui Ni, Bolv Xiao, Zongyi Ma (2025). Fabrication of welded hybrid joints of aluminum alloys and polymer composites with significantly enhanced long-term reliability. Int. Journal of Minerals, Metallurgy and Materials (矿物冶金与材料学报). https://doi.org/10.1007/s12613-025-3244-1
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Frequently Asked Questions
What is the main challenge in joining metals and polymer composites?
The main challenge is the significant differences in physical and chemical properties between metals and polymer composites, which make reliable joining difficult.
How does laser surface treatment improve the reliability of friction lap welded joints?
Laser surface treatment creates micro-mechanical interlocking between the polymer composite and aluminum alloy, and modifies the stress distribution along the joint interface, thereby enhancing long-term reliability.
What was the effect of accelerated aging on the joints without laser treatment?
Without laser treatment, the joints exhibited a 91% reduction in tensile shear force after 7 days of accelerated aging tests.
What was the performance of laser-treated joints after 35 days of accelerated aging?
Laser-treated joints showed only a 26% reduction in tensile shear force even after 35 days of accelerated aging tests, indicating significantly enhanced reliability.
Where did fractures occur in the tensile specimens?
Fractures occurred across the composite plates rather than along the joint interface, indicating strong interfacial bonding.
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