Hybrid-Dissimilar Joints for Lightweight Structures

The adoption of emerging technologies, such as additive manufacturing of metals, improves the sustainability and circularity of industrial processes, by minimising waste through the precise use of materials. Selective laser melting is widely used to produce components with complex geometries in various structural alloys, meeting the needs of various industries, including shipbuilding. The aim of this research is the evaluation of the mechanical behaviour of metal-composite joints for lightweight structures. Two types of additive manufactured specimens, subjected to tensile and three point bending loadings, were considered in this study. The first one consists of additive manufactured AlSi10Mg, the second of a layered structure in which the bulk material (additive manufactured AlSi10Mg) is coated with carbon fibre reinforced skins. Both types are further divided into three groups, according to the 3D building direction: 0°, 45°, 90°. The Digital Image Correlation technique was applied during tensile tests for strain calculation. Non-destructive evaluation, using digital microscopy and infrared thermography, was carried out for the analysis of failure modes and damage. The analysis of the fracture surfaces highlighted a brittle behaviour. The investigated layered structures could be applied for replacing the traditional structure of the aluminium boats with the advantages of the additive manufacturing technology for the aluminium material and the high mechanical performance for the carbon fibre composite material.