Abstract
Implementation of carbon fiber reinforced polymer (CFRP) composites in vehicle structures requires improved CFRP-metal joints. Aluminum alloy (AA) is joined to CFRP using ultrasonic additive manufacturing (UAM). To quantify the mechanical performance of UAM CFRP-AA joints, top-hat and double-hat CFRP-AA hybrid structures are prepared by joining aluminum flanges of CFRP hat sections to AA sheet or to another CFRP hat using resistance spot welding (RSW). Top-hat structures are tested in four-point bending; double-hat structures are tested in dynamic axial crush and quasi-static torsion. The structures with UAM CFRP-AA joints achieve higher energy absorption efficiency than the benchmark in all test modalities.
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