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Pull the pin challenge level 3712/28/2023 ![]() Fig. 1a illustrates a typical bolted joining process of a metallic hinge with CFRP composite panel. Current joining practice of dissimilar materials is generally limited to the use of metallic fasteners, such as in the case of trailing edge devices or the metallic hinge bolted to CFRP composite panels on the Airbus A330 undercarriage door. With the increasing adoption of carbon fibre-reinforced polymer (CFRP) composites in many industry sectors as a replacement for metallic components, the use of hybrid metal-composite joints is becoming more common, and the need to optimise the connection between dissimilar materials is a key challenge. ![]() The work provides new correlation between pin behaviour in isolation and in multi-pin joints, highlights the importance of strong pin-composite adhesion for joint performance, and demonstrates an analysis methodology suitable for design of pin-reinforced composites and metal-composite hybrid joints. We lastly show FE models using the pull-out response characterised in single pin tests give excellent predictions of experimental behaviour in multi-pin joints with no additional calibration. We also determined that the enhanced bonding increased the maximum pin load and Mode I initiation fracture toughness by around 250%, with no pin-composite debonding during cure. Consequently, the pins enabled a 365% increase in Mode I steady-state fracture toughness. We found the pin-composite interfacial strength was 3.5 times higher than comparable carbon fibre z-pins due to excellent adhesion characteristics of the as-manufactured pin surface. Single pin specimens under pull-out loading and Mode I crack growth specimens were investigated using experimental, finite element (FE) and analytical methods. Here, we investigate Selective Laser Melting manufactured titanium with pins adhered to carbon fibre-reinforced polymer composite. Hybrid metal-composite joints that integrate pins on the metal adherend are a novel joining concept, and knowledge regarding single pin performance and correlation to multi-pin joint behaviour is critically lacking.
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