Fatigue strength of a hybrid joint formed between a PA6-GF60 polymer matrix and a S420MC steel insert

•Presented is an innovative polymer-metal hybrid joint.•Durability curves and their scatter were calculated using the DASA procedure.•Specimens with the embossed steel insert outperformed in static and dynamic tests.

A vehicle’s brake pedal is considered to be one of its most important safety components. In the past, vehicle weight-reduction initiatives resulted in a highly optimized design of steel brake pedal with an increased strength-to-weight ratio. However, any further reduction in the weight of the brake pedal is only possible by using combined, i.e., hybrid, materials. In this case the joint between the two different materials in the hybrid arrangement must be as strong as possible. Many methods for improving the joint between two highly dissimilar materials are known from the literature, but conventional joining techniques lack either the fatigue resistance, because of a poor notch-effect design (shape-based joints), or are unsuitable for low-cost serial production (material-based joints). This article presents an innovative approach to joining the reinforcing insert with a glass-fiber-reinforced polyamide 6 (PA6-GF) base structure, where the reinforcing insert is molded into the PA6-GF. The improved shape of the reinforcing insert contributes the required strength, while the PA6-GF base structure provides the final form of the specimen/product. The innovative shape of the metal insert not only provides the strength of the component; it also ensures the proper joint between the two dissimilar materials. For different types of reinforcing inserts static durability tests as well as fatigue-life tests of the insert-PA6-GF-matrix joints were performed. Our experimental research shows that the most promising shape-based hybrid joints reported in the literature are not the best solution when the hybrid joint’s fatigue life is the decisive criterion for a product’s durability.