Investigation of the Mechanical Strength of CFRP with Co-Cured Additively Manufactured Metal Inserts

Multi-material structures, combining metal alloys and composite materials, are widely used in industries such as aeronautics. Traditional joining methods, such as riveting or adhesives, require surface treatment, drilling holes, alignment, and cleaning of residues, adding time and cost to production. This paper presents the numerical modeling and experimental validation of metal-composite joints based on surface morphology modification through additive manufacturing (AM). We used laser-based powder bed fusion (LB PBF) to build the metal part, creating a superficial pattern of three-dimensional elements with various shapes and sizes. These elements act as anchors for the composite, creating local interactions with the carbon fibers. We built laboratory samples using carbon fiber fabrics with a 90° orientation and resin impregnation. After curing at ambient pressure and temperature, we fabricated tensile samples. The results provide design information about the joint strength with respect to the characteristics of the 3D anchors used at the interface.