Additive Manufacturing of Titanium with Different Surface Structures for Adhesive Bonding and Thermal Direct Joining with Fiber-Reinforced Polyether-Ether-Ketone (PEEK) for Lightweight Design Applications

Hybrid joints consisting of metals and fiber-reinforced polymer composites exhibit highly desirable properties for many lightweight design applications. This study investigates the potential additively manufactured surface structures enhancing bond strength such in comparison to face milled laser structured surfaces. Titanium samples with different (as-built surface, groove-, pin-shaped structures) were via electron beam melting joined carbon polyether-ether-ketone (PEEK) adhesive bonding thermal direct joining, respectively. Bond was evaluated by tensile shear testing. Samples exposed salt spray testing 1000 h studying stability under harsh environmental conditions. The initial strengths competitive or some cases even exceeded values achieved structuring both investigated joining methods. most promising results found structures. However, hybrid tended be more susceptible degradation during exposure. It is concluded that can a viable alternative metal-polymer joints, thus opening up new potentials design.