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Materially bonded hybrid systems with precisely adjusted interfacial properties are of great scientific and industrial interest with regard to lightweight construction. In the present study, a material composite of carbon fiber reinforced plastic (CFRP) and galvanized steel is considered, where the metallic surface is laser structured in order to improve the adhesion properties. The resulting joining properties will be elicited by tensile shear tests in comparison to an alkaline cleaned surface condition and blind riveting. The potential of direct-joined hybrid systems with laser-structured substrate surfaces will also be considered using an automotive roof frame as an example. In the tensile shear test, the direct-joined hybrid joint with laser-structured metal substrate achieves significantly higher joint strengths than after alkaline cleaning. Compared to an aluminum/steel reference structure, the CFRP/steel roof frame exhibits a significant weight advantage with superior mechanical properties under flexural and compressive loading.

Co-bonding of carbon fibre-reinforced epoxy and galvanised steel with laser structured interface for automotive applications