Modeling and Experimental Validation of CFRP-Metal Joints Utilizing 3D Additively Manufactured Anchors

Abstract The joining techniques between carbon fiber reinforced polymer (CFRP) and metal are of great importance in many areas of structural mechanics where the optimization of weight, rigidity, and strength is a necessity (such as aeronautics, vehicles, energy generation, and biomechanics). As a result, several types of metal–composite joints have been manufactured using different methods, with the 3D metal anchor solution attracting significant attention. This study evaluates different anchor geometries applied to single lap joints through preliminary finite element method (FEM) simulations and experimental validation on joints between CFRP and Inconel 625 produced via a laser beam powder bed fusion (LB-PBF) additive process. The models proposed increase in complexity. The homogenization process is employed to determine the equivalent properties of the joint region that is occupied by metal anchors and CFRP. The model also supports topology parametrization to assess the impact of anchor geometry on structural properties. The study provides experimental validation of joint strength under tensile load for various anchoring surface topologies.