Abstract
The fabrication of strong and lightweight polycarbonate and AlSi10Mg aluminum alloy hybrid joints entirely through additive manufacturing was successfully demonstrated. AlSi10Mg substrate with submillimeter-sized mushroom-shaped structures on the surface were printed by laser powder bed fusion (LPBF), being subsequently hybridized with PC via fused filament fabrication (FFF) using the AddJoining approach. The structures drawn on the metal surface were properly filled with the polymer during printing, ensuring good interfacial adhesion and thus providing PC/AlSi10Mg hybrid joints with excellent lap-shear strength of 10.8 ± 0.6 MPa.
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