Carbon Fibre Reinforced Research Articles

Experimental and theoretical study on the flexural behaviour of RC beams strengthened with externally bonded reinforcement on grooves CFRP laminates

This paper presents a study on the flexural capacity of Reinforced Concrete (RC) beams strengthened with Externally Bonded Reinforcement on Grooves (EBROG) Carbon Fibre Reinforced Polymer (CFRP) laminates. Thirteen single-shear tests and seven RC beams strengthened with CFRP are examined, comparing Externally Bonded Reinforcement (EBR) and EBROG techniques with different groove distributions. The results showed that EBROG improved the bond and flexural performance. Comparison with existing prediction models reveals that while the literature models accurately predict EBR results, they underestimated the bending capacity for EBROG due to calibration based on EBR bond parameters. Consequently, a numerical model is developed to simulate Intermediate Crack Debonding (ICD) for various bond-slip laws, applicable to the different strengthening techniques. The proposed model is validated using experimental flexural tests and calibrated bond-slip laws obtained from single-shear tests, demonstrating accurate prediction of ICD failure for both EBR and EBROG.

Distribution and reinforcement effect of carbon fiber at the interface in injection welding of polyamide 6 composites

AbstractTo meet the lightweight production requirements of automobiles and achieve high strength, reinforced thermoplastic composite materials are gradually replacing metal materials. Injection molding is the preferred manufacturing method to enable the production of complex‐shaped parts, facilitate production, and reduce costs. In this study, carbon fiber (CF) was added to the commonly used resin‐reinforcing material, polyamide (nylon) PA6, to create a CF‐reinforced thermoplastic composite (polyamide 6 [PA6]/CF) that was welded using injection molding. This study not only investigates the impact of different welding conditions on shear strength but also discusses the sequence of welding. Achieving 85% of the shear strength of the PA6 base material under ideal circumstances. The CF distribution and reinforcement mechanism were analyzed by observing the connection interface and cross section using a polarizing microscope and a scanning electron microscope. When PA6/CF was used as the secondary molded body, the welding results were better. The addition of CF had a significant strengthening effect on the strength of the PA6 injection welding.Highlights Carbon fiber‐reinforced thermoplastic composite materials were prepared, and welding with PA6 was achieved using the injection molding method. The optimal welding parameters were determined by varying the mold, injection speed, injection temperature, and order of injection. The maximum welding shear strength reached 85% of the base material shear strength. The positive effect of specific fiber distribution on welding strength was analyzed by observing the interface using a scanning electron microscope and a polarizing microscope. This study provides valuable insights into the optimization of welding processes for carbon fiber thermoplastic composite materials, offering possibilities for connecting dissimilar materials with poor compatibility.

Interface engineering of carbon fiber composites using CNT: A review

AbstractThis paper aims to explore the potential of carbon nanotubes (CNTs) in enhancing the structural capability and multifunctionality of carbon fiber composites in aerospace applications, primarily by focusing on interfacial applications. The conventional method of dispersing CNTs in a matrix is not fully efficient in exploiting the mechanical and multifunctional performance of CNTs. Hence, the use of CNTs at the interface or as a coating on the surface of carbon fibers has been suggested as a means of achieving multifunctionality, in addition to enhanced mechanical performance. The paper presents an overview of the various processes for growing CNTs on carbon fiber surfaces and examines the effects of CNT geometry and growth parameters on the properties of grafted fibers and their composites. Furthermore, it discusses the potential improvements in thermal and electrical conductivity achievable by incorporating CNTs at the interface, as well as the benefits of using CNTs as a sizing layer for carbon fibers, including enhanced fracture toughness and resistance to delamination.Highlights Comprehensive study of interface engineering in carbon fibers and Carbon Fibre Reinforced Plastic (CFRPs) using carbon nanotubes (CNTs). Improved transverse mechanical properties and overall thermal and electrical properties. Multifunctional applications possible with the use of CNT. Both experimental and numerical studies reviewed.

Preparation and frictional characteristics of solid lubrication coating on CFRP surface

ABSTRACT Solid lubricating coatings were applied onto Carbon Fibre Reinforced Polymer (CFRP) substrates, using epoxy resin as the adhesive agent, graphite (C) and molybdenum disulphide (MoS2) as lubricating components, and alumina (Al2O3) as the functional filler. The test parts were prepared by spraying technology and co-curing process. The mechanical properties of the coating were evaluated using Bar hardness and wear rate tests, while the microstructure of the coating was analysed using EDS elemental analysis technology. The test results revealed that the filler content had a significant impact on the mechanical properties. The performance of the coating was determined by the formation of a lubricating film, which resulted from the accumulation of lubricant and reinforcing material during external friction. Scheme T7 yielded the best coating performance with a ratio of epoxy resin to molybdenum disulphide to graphite to alumina of 20:8:3:2.

Unbonded Pre-Tensioned CF-Laminates Mechanically Anchored to HSC Beams as a Sustainable Repair Solution for Detachment of Bonded CF-Laminates

The present article outlines a Finite Element Model (FEM) that was created and validated by comparing it to prior experimental investigations to estimate the flexural performance of HSC beams strengthened with exterior bonded, unbonded, and unbonded pre-tensioned Carbon Fibre Reinforced Polymer (CFRP) sheets in several patterns. Nonlinear analysis was performed on three-point-loaded beams using ANSYS software, incorporating the constitutive characteristics of various components (concrete, CFRP, and steel). The comparison of FE-models and experimental data, namely for load-deflection curves, crack patterns, and failure modes, revealed that the developed numerical FE-models and experimental outcomes are in good accord. There has been numerous prior research on the behavior of beams strengthened with externally bonded CFRP sheets, but few on those reinforced with externally unbonded CFRP laminates, and even fewer on HSC beams reinforced with externally unbonded pre-tensioned CFRP laminates. Therefore, the major contribution of this article is to investigate the flexural behavior of HSC beams strengthened utilizing externally unbonded pre-tensioned CFRP laminates. The analysis revealed that the bending performance of RC-beams strengthened using external unbonded pre-tensioned CFRP-laminates is quite similar to that of bonded CFRP-strengthened beams, indicating a high potential for tackling the durability issues caused by detachment of bonded CFRP-strips in such structural elements. The existence of a fully wrapped CF sheet forced the beam to develop diagonal shear cracks in the region between the wrapped CF sheet and beam supports while also enhancing the flexural cracked zone at mid-span to change from smeared to discrete fractures. The flexural fractures spread over a deeper and wider area of the beam as a result of the incorporation of a half-wrap CF laminate. Externally unbonded CFRP-sheets pre-tensioned with 45% of the CFRP ultimate strength utilizing various patterns (straight and U-wrap) performed similarly to bonded CFRP-sheets, with a slight boost in load capacity of around 4.5% and notable reduces in deflection ranging from 9.7% to 16.24%. Using exterior unbonded CFRP laminates to strengthen RC-beams resulted in a flexural capacity increase ranging from 22.3% for NC beams to 71.6% for HSC beams.

Carbon fiber reinforced polyethylene composite adhesive at elevated temperatures

The development of multi-layer-multi-material thermoplastic structures necessitates the bonding of dissimilar materials with varying mechanical, chemical, barrier, and thermal properties. Thermoplastic adhesives, such as maleic anhydride grafted polyethylene (PE-MAH), are advantageous over thermoset adhesives given their similar manufacturability, and numerous benefits as sustainable materials in compliance with strict environmental regulation in construction, automotive, and energy industries. A key drawback is that PE-MAH demonstrates weak adhesive properties at elevated temperatures. In this study, the adhesion strength of carbon fiber (CF) reinforced PE-MAH at elevated temperatures were evaluated using a novel method of T-peel test under a controlled environment. Significant improvements of 71% and 295% increase in peel strength at 90 °C and 110 °C, respectively, were achieved with CF reinforcement over neat PE-MAH. The improving mechanisms were discussed on both macro-level, i.e., enhanced peel zone and eliminating crazing, and micro-level, i.e., transferred stress and dispersed energy into micro peel zones. This study demonstrates the efficacy of tailoring the adhesion strength of thermoplastic composite adhesive for significantly improved performance at elevated temperatures.

In Situ, Real-Time Temperature Mapping and Thermal FE Simulations of Large-Format 3D Printed PETG/CF Vertical Wall.

This work focuses on simulating the thermal history of a vertical wall consisting of a thermoplastic composite material, poly(ethylene terephthalate) glycol (PETG) with short carbon fiber reinforcement, manufactured using a Big Area Additive Manufacturing (BAAM) system. The incremental deposition process used in additive manufacturing, which corresponds to the repeated deposition of hot material onto cooler material, contributes to the presence of residual stresses and part warping. The prediction of these mechanisms is dependent on thermal history of the part, and the major motivation of this work was to improve the accuracy of finite element (FE) models used to quantify the thermal history of large-format additively manufactured parts. Thermocouples were placed throughout the part at varying heights to measure temperature as a function of time. The FE model developed found a thermal contact conductance between the printed part and the bed of 10 W/m2K and convection coefficient values that linearly varied from 3 to 15 W/m2K through the wall height when making a temperature comparison with the output from the thermocouples. It is also demonstrated that the FE model with a constant convection coefficient under-predicts model temperature at the beginning of the manufacturing process when compared against the model with a variable convection coefficient. The impact of this difference was seen in the stress values, which were larger for the model with a constant convection coefficient. Finally, a correlation equation was derived which allows the findings to be generalized to other vertical structures manufactured on the BAAM. In summary, this work offers valuable insights on material characterization, real-time thermocouple placement, and FE modeling of large-format additively manufactured parts.

Mineral-impregnated carbon-fiber based reinforcing grids as thermal energy harvesters: A proof-of-concept study towards multifunctional building materials

This proof-of-concept study demonstrates for the first time the fabrication of a multifunctional reinforcing grid-building material within a thermoelectric element generator (TEG) configuration. Commercially available carbon fiber yarns, which possess inherent Seebeck coefficient (S) values of −2.5 μV/K (n-type) and +7.4 μV/K (p-type), were thoroughly investigated prior to their impregnation with a geopolymer (GP)-based suspension. The resulting hardened mineral-impregnated carbon-fiber (MCF) reinforcements were subsequently tested regarding their physicochemical and mechanical properties. Afterward, individual MCFs were employed as n-/p-type thermoelements to assemble a grid-like TEG consisting of five serially interconnected junctions. The TEG-enabled reinforcing grid exhibited a voltage output of 1.8 mV, corresponding to a generated power of 22.3 nW upon exposure to an in-plane temperature difference (ΔT) of 50 K. Multifunctional building materials are envisaged to exploit thermal gradients on a large-scale during their service lifetime, contributing towards zero energy consumption constructions.

Out-of-autoclave molding of carbon fiber laminates by consolidation with shape memory polymer foams

Carbon fiber reinforced (CFR) laminates have been manufactured by an innovative out-of-autoclave (OOA) process thanks to the use of smart materials. In this study, for the first time, a shape memory polymer (SMP) foam has been used into a pressure dome to apply the consolidation pressure to the laminate. Heat for resin curing was supplied by a thermal blanket between the laminate and the SMP foam. In order to test the OOA molding process, 24-ply CFR laminates were manufactured and tested. For comparison and reference, CFR laminates were also molded by traditional vacuum bagging and autoclave curing. Samples for bending tests were extracted from OOA and autoclave molded plates. Results show that the SMP-OOA process is able to provide optimal laminate consolidation, despite of the low applied pressure (about 1 bar). A comparable density and ply thickness was measured on samples by the innovative and the conventional molding process, whereas a higher bending strength (+5%) was found on OOA samples. A higher dispersion was also observed for the properties of SMP-OOA molded laminates in comparison with autoclave, probably due to the prototyping nature of the molding technique in comparison with the well-known autoclave practice. Nevertheless, the final quality of the molded laminates is very high, and the SMP-OOA process is a very promising candidate as a technology to repair CFR structures.

A 3D printed continuous carbon fiber reinforced composite with function of self-detecting and self-healing of internal damages

Realizing the self-detecting and self-healing of internal damage is of great significance for ensuring the safe service and extending the service life of carbon fiber reinforced (CFR) composites. Here, a CFR thermoplastic composite composed of “long CFs - short CFs” was designed and prepared through a hybrid 3D printing method. Firstly, by multi-threaded laying and hybrid printing of conductive continuous CF inside the material, it shows that there is good consistency between the mechanical properties and conductive properties induced by internal damages, providing an important non-destructive detection method for the determination and danger warning of internal damages in the material. Secondly, the printed “long CFs - short CFs” combinated structure can induce a synergistic effect in the coupling between the composite and microwave. This synergistic effect can avoid the ignition of long CFs and the local melting of short CFR polymer, thereby making it possible to realize the non-contact microwave healing of local damages. The healed material significantly improves the toughness while ensuring almost initial strength. This study is of positive significance for achieving the 3D printing of multifunctional implementation of CF composites with “nondestructive detecting - accurate positioning - self-healing” of damages.

Precision and Dimensional Stability of Bonded Joints of Carbon-Fibre-Reinforced Polymers Parts

This article aims to investigate the accuracy and dimensional stability of bonded metal and CFRP (Carbon Fibre Reinforced Plastic) adherends. The motivation behind this study was to assess the suitability of CFRP for optical devices through the evaluation of precision bonding technology. A binocular was selected as a reference optical device. A technological sample was designed, with required total runout of key dimensions 0.05 mm. The sample underwent testing according to ISO 9022-1. The total runout was evaluated after production and environmental tests. Eight out of 15 samples were turned after gluing due to insufficient accuracy. None of the turned samples exceeded the total runout deviation of 0.01 mm, and the average value of the maximal deviation was 0.0041 mm. The noncalibrated samples performed significantly worse with the average value of the maximal deviation of 0.0164 mm. The measurements during the climatic tests showed that the largest deviation (on average 77.6% of the maximum achieved deviation) occurs at the first temperature loading. Subsequent temperature cycles caused lower deviations. The results highlight the significance of addressing deformations resulting from adhesive volume shrinkage-induced stress as a crucial factor in precision bonding technology.

Biobased boronic ester vitrimer resin from epoxidized linseed oil for recyclable carbon fiber composites

In the last decades fiber-reinforced polymer composites (FRPC) have seen an enormous growth however, at the end of their lifetime, FRPC made of epoxy resins cannot be easily recycled because of the permanently crosslinked structure of the resins. Since the fibrous reinforcements usually have high costs, the possibility of developing recyclable FRPC is very advantageous both from environmental and economical point of view.To address this increasing need of the market, we developed a recyclable, environmentally friendly vitrimer resin from epoxidized linseed oil and a boronic ester cross-linker. Using the vitrimer as a matrix, carbon fiber-reinforced composites, with mechanical performance similar to the ones prepared with a conventional epoxy resin, were obtained. Moreover, the composites could be conveniently recycled under mild conditions by reversible hydrolysis of the boronic ester crosslinks using aqueous EtOH, recovering both the carbon fiber reinforcement and the vitrimer matrix.

Influences of Main Machining Process Parameters and Tool Wear on The Machining Damage Generated During Edge Milling CFRP Composites

Machining Carbon Fibre Reinforced Plastics (CFRPs) composites are typically accompanied by the appearance of machining damage which strongly impacts the structural integrity of composite parts during their service lives. Studying the correlation between machining damage and its affected factors has still been an open issue. Hence, it is necessary to do more research. This study focuses on investigating the influences of main process parameters and tool wear phenomenon in terms of machining length on the machining quality which was characterized by the surface roughness criterion, the ten-point max, Rz. A full factorial design of experiments was conducted including three levels of feed speed and two degrees of spindle speed. The results revealed that machining damage was mainly influenced by process parameters at a small machining distance, whereas at a longer machining distance, tool wear had a dominant effect on the machining quality than machining parameters. These findings could provide guidelines for selecting suitable machining parameters to enhance the machining quality of CFRP.

High-temperature fracture behavior of carbon fiber reinforced PEEK composites fabricated via fused filament fabrication

This study investigates the influence of temperature on the mechanical and fracture properties of carbon fiber reinforced (CF) polyetheretherketone (PEEK) composites, with a specific focus on different layer heights used in the additive manufacturing process. Tensile and compact tension fracture tests were conducted at varying temperatures to evaluate the orthotropic mechanical properties and crack growth resistance curves, respectively. The key findings underscore the pronounced orthotropic mechanical behavior in additively manufactured CF-PEEK composites, showing substantial variations of up to 50% in Young's modulus and yield strength across orientations. Additionally, as test temperatures increase, crack initiation becomes easier, indicating reduced crack resistance at elevated temperatures. Notably, the effect of layer height on initiation toughness is relatively minor compared to temperature. Moreover, the study reveals that fracture energy for crack growth is less temperature-sensitive but depends on layer height, with larger defects in taller layers resulting in decreased damage resistance. These findings stress the importance of considering the distinct sensitivities of initiation and steady-state fracture energies to temperature, emphasizing the critical role of effective fracture toughness in evaluating material resistance to high-temperature fractures. These observations contribute to our understanding of the mechanical and fracture behavior of CF-PEEK composites under high operating temperatures. This understanding facilitates the optimization of their manufacturing processes and their application in various industries such as aerospace.

Microstructures and formation mechanism of continuous carbon fiber-reinforced (TiZrHfNbTa)C high-entropy ceramic composites fabricated via high-entropy alloy reactive melt infiltration

Using TiZrHfNbTa high-entropy alloys as cation sources and carbon matrix in carbon fiber-reinforced carbon (Cf/C) preforms as carbon sources, this study presents rapid construction of dense, continuous Cf-reinforced (TiZrHfNbTa)C high-entropy ceramic (Cf/HEC) composites based on reactive melt infiltration (referred to as Cf/HECRMI composites). The results consistently indicate the uniform distribution of elements in the ceramic phase. Based on X-ray diffraction patterns, the ceramic phase was inferred as a (TiZrHfNbTa)C HEC phase. Cf/HECRMI composites can form because the TiZrHfNbTa high-entropy alloy reacts with the carbon matrix to form uniform ceramic monomers, which spontaneously assemble into the (TiZrHfNbTa)C HEC phase under high-temperature conditions. Owing to the dense microstructures, the high strength of the (TiZrHfNbTa)C phase, high strength and toughness of the residual TiZrHfNbTa alloy phase, and Cf reinforcement, Cf/HECRMI composites exhibit excellent mechanical properties with a bending strength of 584.2 MPa. These composites also possess outstanding ablation resistance, with linear and mass rates of 0.6 μm s−1 and 0.9 mg s−1, respectively, under an ablation time of 180 s and ablation temperature maintained at ∼2000 °C. The high ablation resistance can be attributed to dense, stable, and highly viscous complex oxides (HfZrO4, TiNbTaO7, Hf6Ta2O17, Nb2Zr6O17, ZrO2, and HfO2) formed on the sample surfaces.

Influence of distributed out-of-plane waviness defects on the mechanical behavior of CFRP laminates

One of the most common defects induced during manufacturing of laminates is out-of-plane fibre waviness. This defect significantly affects the mechanical behavior of the laminate and reduces fatigue life and the load capacity of the material. Therefore, it is important to understand the impact of fibre waviness on the performance of composite laminates. In this work, multiple out-of-plane waves have been introduced throughout a Carbon Fibre Reinforced Polymer (CFRP) laminate at different thickness positions. The specimens were tested under tensile loading and an analysis of the surface of the laminate has been carried out by means of Digital Image Correlation (DIC). The results obtained by DIC were able to predict the apparent strain of the laminate quite accurately, as well as locate up to seven undulations at different depths. It was proved that a laminate with multiple wrinkles has 16% less tensile load strength. The results were used to validate different Finite Element (FE) models of the laminate showing a good agreement. These simple models were able to predict the initiation and propagation of failure in both the matrix and the fibre.

Feasibility of additively manufacturing synthetic bone for sports personal protective equipment applications

Human limb surrogates, of varying biofidelity, are used in the performance assessment of sports personal protective equipment (PPE). Such biofidelic surrogates have incorporated soft tissue simulants (silicones) and synthetic bone (short fibre filled epoxy). Testing surrogates incorporating realistic synthetic bone could help to further our knowledge of fracture trauma mechanics, and applications such as the effectiveness of sports PPE. Limb surrogates with embedded synthetic bone are rarely tested to fracture, mainly due to the effort and cost of replacing them. This paper proposes additive manufacturing of synthetic bones, with appropriate bone like fracture characteristics, potentially making them more accessible and cost effective. A Markforged® X7™ printer was used as it prints a base filament (Onyx™) alongside a continuous strand of reinforcement (e.g., carbon fibre). The properties of specimens from this printer vary with the type, volume fraction and position of reinforcement. Bar specimens (10 × 4 × 120 mm) with varying amounts of carbon fibre reinforcement were printed for three-point bend testing to determine the feasibility of achieving mechanical properties close to compact bone (bending modulus of ∼15 GPa, bending strength of ∼180 MPa). Bending strength for the various bar specimens ranged from 32 to 378 MPa, and modulus values ranged from 1.5 to 25.8 GPa. Based on these results, four 140 mm long oval shaped cylindrical specimens of ø14 and ø16 mm were printed to represent a basic radius bone model. Three-point bend testing of these bone models showed similar bending modulus (3.8 to 5.3 GPa vs. 3.66 to 14.8 GPa) to radius bones reported in the literature, but higher bending strength (147 to 200 MPa vs. 80.31 ± 14.55 MPa).

Synthesis and characterization of DOE-based stir-cast hybrid aluminum composite reinforced with graphene nanoplatelets and cerium oxide

Purpose This research outlines the development and characterization of advanced composite materials and their potential applications in the aerospace industry for interior applications. Advanced composites, such as carbon-fiber-reinforced polymers and ceramic matrix composites, offer significant advantages over traditional metallic materials in terms of weight reduction, stiffness and strength. These materials have been used in various aerospace applications, including aircraft, engines and thermal protection systems. Design/methodology/approach The development of design of experiment–based hybrid aluminum composites using the stir-casting technique has further enhanced the performance and cost-effectiveness of these materials. The design of the experiment was followed to fabricate hybrid composites with nano cerium oxide (nCeO2) and graphene nanoplatelets (GNPs) as reinforcements in the Al-6061 matrix. Findings The Al6061 + 3% nCeO2 + 3% GNPs exhibited a high hardness of 119.6 VHN. The ultimate tensile strength and yield strength are 113.666 MPa and 73.08 MPa, respectively. A uniform distribution of reinforcement particulates was achieved with 3 Wt.% of each reinforcement in the matrix material, which is analyzed using scanning electron microscopy. Fractography revealed that brittle and ductile fractures caused the failure of the fractured specimens in the tensile test. Practical implications The manufactured aluminum composite can be applied in a range of exterior and interior structural parts like wings, wing boxes, motors, gears, engines, antennas, floor beams, etc. The fan case material of the GEnx engine (currently using carbon-fiber reinforcement plastic) for the Boeing 7E7 can be another replacement with manufactured hybrid aluminum composite, which predicts weight savings per engine of close to 120 kg. Originality/value The development of hybrid reinforcements, where two or more types of reinforcements are used in combination, is also a novel approach to improving the properties of these composites. Advanced composite materials are known for their high strength-to-weight ratio. If the newly developed composite material demonstrates superior properties, it can potentially be used to replace traditional materials in aircraft manufacturing. By reducing the weight of aircraft structures, fuel efficiency can be improved, leading to reduced operating costs and environmental impact. This allows for a more customized solution for specific application requirements and can lead to further advancements in materials science and technology.

Influence of printing parameters and short carbon fibre reinforcement on fatigue behaviour, dimensional accuracy and macrogeometrical deviations of polylactic acid in material extrusion

This paper evaluates the potential of short carbon fibres as a reinforcement material in order to improve the fatigue resistance of PLA. The fatigue behaviour has been analysed through rotational bending fatigue tests. The influence of printing parameters, such as layer thickness, printing temperature and printing speed, on the mechanical behaviour, dimensional accuracy and macrogeometrical deviations of printed parts have also been analysed as they can too interfere with the mechanical behaviour of the parts. The results show that there is no improvement on the mechanical behaviour of the printed parts with the incorporation of short carbon fibres. On the contrary, the fatigue behaviour worsens due to the poor adhesion between the short carbon fibres and the PLA matrix. Fatigue life is reduced by 6% compared to PLA. Focusing only on the printing parameters, it is shown that at the highest temperature allowed, the fatigue behaviour improves a 12%. The Printing speed is the least influential variable, with the layer thickness having the greatest influence, increasing fatigue life by 15% comparing 0.1 mm and 0.3 mm. Therefore, the best combination would be to print with the highest temperature and the highest layer thickness, for this case study. Finally, a parametric relationship is presented in order to relate the layer thickness with the fatigue behaviour.

Adhesion properties of the hybrid system made of laser-structured aluminium EN AW 6082 and CFRP by co-bonding-pressing process

ABSTRACT A parameter investigation for manufacturing a hybrid system through the prepreg pressing process was carried out within the scope of this work to achieve optimal adhesion properties. The hybrid specimen comprises an aluminium sheet of alloy EN AW 6082 in T6 condition and a thermoset Carbon Fibre Reinforced Plastics prepreg. The prepreg pressing process allows the curing reaction of epoxy resin and the joining process to occur simultaneously to avoid an additional bonding process step. The surface of the aluminium sheet was pretreated in advance using a pulsed Nd:YAG laser to enhance the bonding properties. In the first step, the shear edge tests investigated the adhesion properties achieved with different consolidation (temperature, time and pressure) and laser parameters. Then, 3-point bending tests were carried out to investigate the influence of the consolidation parameters on the mechanical properties of the Carbon Fibre Reinforced Plastics-laminate. In this way, the optimal parameter sets for manufacturing hybrid structures were determined.