Achieving a High‐Strength Bonding between Aluminum Alloys and Polymer Composites via Self‐Riveting Welding

Abstract

Great challenges exist in producing reliable welding between metals and polymer composites. In this study, self‐riveting welding (SRW) is employed to obtain metal–polymer hybrid joints with high load‐bearing capability. In this investigation, it is shown that the SRW joints with a prefabricated hole of 5.8 mm in diameter are characterized by fewer void defects with sufficient polymer filling, a tightly bonded joint interface, and a relatively uniform stress distribution along the joint interface during the tensile test, leading to the high load‐bearing capability of the SRW joints. The maximum average tensile force is 1.5 kN. The fracture occurs across the polymer composite rather than along the joint interface. In the results, it is shown that SRW has the potential to be developed into a method for fabricating reliable hybrid joints for the aerospace and automotive industries.