Optimization of Hybrid Composite–Metal Joints: Single Pin

Abstract

Deepening the understanding of composite and metal joint methodologies applied in the aerospace industry is crucial for minimizing operational expenditures. Current investigations are focusing on innovative joining techniques that incorporate additive manufactured rivet pins. This research aims to analyze the mechanical strength of these joints for the effective optimization of pin profiles. Through extensive study of the impact of pin geometry on joint performance, we derived the optimal pin design, considering various initial parameters with the objective of minimizing stress concentration in the pin structure. The joint configurations of metal to composite interfaces were systematically examined using finite element analysis and lap shear testing, which included a singular pin and an adhesive-bonding layer. Numerical simulations reveal that the maximum shear stress in the pin is located at the junction between the base of the pin and the metal plate. By optimizing the shape and dimensions of the pin, both the shear and axial stresses can be significantly mitigated. Following the numerical optimization process, a series of enhanced pins have been produced via additive manufacturing techniques to facilitate mechanical testing. The experimental data obtained align closely with the simulation results, thereby reinforcing the validity of the optimization. The optimal configuration for a single pin, involving a 60° angle and a total height of 3.43 mm, achieves the minimum shear stress. Based on these findings, further investigations are underway to explore optimized designs utilizing multiple pins. This paper presents the results of the single pin study, whereas the findings pertaining to the ongoing investigation on the multi-pin configuration will be disseminated in subsequent publications.