Failure mechanisms of hybrid metal-composite joints with different protrusion densities under a tensile load

The mechanical behaviors of hybrid metal-composite joints with different protrusion densities were investigated by combining numerical and experimental methods. High-fidelity finite element models that considered the failure modes of all components were developed, and specimens based on metal additive manufacturing technology were tested under quasi-static tensile load to verify the numerical calculations. The results showed that the load capacity and the dominant fracture mode of joints were significantly affected by the metal protrusion density. The failure mechanisms of joints under different protrusion conditions exhibited a clear difference, which proved the possibility of an optimal and functional joint design.