Characterization of intrinsic interfaces between fibre-reinforced composites and additively manufactured metal for designing hybrid structures

The combination of additively manufactured metal components with thermoset fibre-reinforced composites provides the possibility to produce hybrid structures with increased functionality and reduced mass. The application in the high-performance sector, for example the implementation of such a hybrid structure in electric drive units in aviation, provides the potential to achieve the high power densities required. The challenges in this regard are the manufacturing, design and dimensioning of the interface between the two components regarding the technical requirements, such as the high temperature range. In this publication, metal specimens are manufactured using selective laser melting (SLM) and then pre-treated. The joint with the composite is obtained in the subsequent infiltration process when the composite part is manufactured. For the experimental characterization of the interface different combinations of fibre-reinforced composites and metals are used. Within roughness measurement the surface of the different materials due to the treatment were analysed and the intrinsic interfaces were microscopically examined. The joint strength is investigated in double lap shear test at different temperatures and the results are discussed based on the fabrication process and the characteristics of the hybrid interface. The results provide the basis for the future design and numerical description of the interfaces.