Applicability of adhesive–embossing hybrid joining process to glass-fiber-reinforced plastic and metallic thin sheets

Adhesive–embossing hybrid joining process was applied to A2017P and three types of glass-fiber-reinforced plastic (GFRP) thin sheets. Optical microscopy shows that a sound A2017P–thermosetting GFRP hybrid joint without crack/delamination in the composite or adhesive failure can be produced by optimizing adhesive thickness, embossing stroke and embossing temperature. The results of tensile shear test indicate that the optimally hybrid-bonded A2017P–GFRP joint exhibits improved load carrying capability, slip displacement and better energy absorbing characteristics than the adhesively bonded joint when subjected to tensile loading. This investigation shows that the adhesive–embossing hybrid joining process is a competitive alternative joining method for the fabrication of ultra lightweight thermosetting GFRP-metal hybrid structures and has great potential for wider applications, which is attributed to its benefits in terms of joining properties, operation simplicity, weight-cost effectiveness and recyclability.