Finite element based optimization of a novel metal-composite-joint

Stephan A. Ucsnik, Rudolf Gradinger, Ulf Noster, Dieter H. Pahr

Research output: Contribution to book/report/conference proceedingChapter in book/report


Aerospace and automotive industries employ three main techniques to set up joints between metal and fibre reinforced plastics parts (FRP); adhesive bonding, mechanical fastening with rives/bolts and a hybrid combination. A new joint technique has been developed to combine the two advantageous mechanisms form-closure and adhesion in a fibre-friendly way. Prior is established through metal structures (pins) which are perpendicularly welded onto metal surfaces with an arc-welding-process. They intrude into the FRP during lay-up and therefore set up a first connection. The composite-matrix is responsible for latter adhesive bonding and final form closure. Finite-element-analyses of cylindrically shaped joints are carried out to get detailed knowledge of the influence of parameters like pin-number, pin-position, pin-height, pin-form sleeve-geometry, and stiffness behaviour. Long calculation times of 3D-models lead to the introduction of a corresponding 2D-axisymmetric-model which is used to run parameter-studies within a reasonable time. For this novel technique the combination of fibre-friendly form closure and adhesive bonding of interface plays a major role. A well selected amount of vertical reinforcements, their placement and geometrical dimensions will lead to a stiffer joint. Goal is to minimize fibre-deletion and overlap length to improve load-transfer and joint-strength, to reduce weight in high-strength-applications as well as the avoidance of safety rivets.

Original languageEnglish
Title of host publicationIst EUCOMAS
Number of pages9
Publication statusPublished - 2008
Externally publishedYes

Publication series

NameVDI Berichte
ISSN (Print)0083-5560

ASJC Scopus subject areas

  • General Engineering


Dive into the research topics of 'Finite element based optimization of a novel metal-composite-joint'. Together they form a unique fingerprint.

Cite this