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Fiber reinforced plastic (FRP) materials are often used in combination with other materials. Hence, it is necessary to join FRP with other, mostly metallic structures in a material-appropriate way. The joining technique is therefore a key technology for exploiting the lightweight potential of fiberreinforced plastics in multi-material structures. A new hybrid joining method allows the combination of adhesive bonding and form-fitting elements in order to join FRP and metallic components. The adhesive bond is achieved by the matrix resin itself, which is required to fabricate the FRP. The form-fit is realized by small scale pin structures which are welded upon the metallic base material and are afterwards embedded into the FRP. Combining the two principles of adhesive bonding and form-fitting elements causes a multi-step failure behavior, which allows sensor-based monitoring of the joining zone. The adhesive failure can be detected at an early stage in order to prevent critical component failure.

Sensor-Monitored Multi-Material Joint made ofFiber-Reinforced Plastic (FRP) and Metal-“Smart Multi-Material Joint”