journal article·2026-02

Shear Strength Enhancement of Injection-Molded Metal-Polymer Composite Joints Using Z-Pins Manufactured Through Fused Filament Fabrication

Run Chen, Xin Lv, Qixin Zhao, Mengjia Li, Yuan Zhao, Sisi Wang, Shiju E, Linlin Wang

Applied Composite Materials· Volume 33· Issue 1
Publisher page

Abstract

No abstract is available for this record. The assistant can identify its topic from the title, but cannot infer the study’s results.

Source: Not provided · Quality: missing

Research context

OpenAlex topics: Advanced Welding Techniques Analysis · Mechanical Behavior of Composites · Cellular and Composite Structures

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (61)

Show source-provided references
1. Dlugosch, M., Volk, M., Lukaszewicz, D., Fritsch, J., Hiermaier, S.: Suitability assessments for advanced composite-metal hybrid material systems in automotive crash structural applications. Int. J. Automot. Compos. 3(1), 14–28 (2017). https://doi.org/10.1504/IJAUTOC.2017.1000765110.1504/IJAUTOC.2017.10007651 ↗
2. Vasconcelos, R.L., Oliveira, G.H.M., Amancio-Filho, S.T., Canto, L.B.: Injection overmolding of polymer‐metal hybrid structures: A review. Polym. Eng. Sci. 63(3), 691–722 (2023). https://doi.org/10.1002/pen.2624410.1002/pen.26244 ↗
3. Amancio-Filho, S.T., dos Santos, J.F.: Joining of polymers and polymer-metal hybrid structures: Recent developments and trends. Polym. Eng. Sci. 49(8), 1461–1476 (2009). https://doi.org/10.1002/pen.2142410.1002/pen.21424 ↗
4. Zhang, Y., Sun, L., Li, L., Huang, B., Wang, T., Wang, Y.: Direct injection molding and mechanical properties of high strength steel/composite hybrids. Compos. Struct. 210, 70–81 (2019). https://doi.org/10.1016/j.compstruct.2018.11.03510.1016/j.compstruct.2018.11.035 ↗
5. Dlugosch, M., Lukaszewicz, D., Fritsch, J., Hiermaier., S.: Experimental investigation of hybrid material systems consisting of advanced composites and sheet metal. Compos. Struct. 152, 840–849 (2016). https://doi.org/10.1016/j.compstruct.2016.06.02910.1016/j.compstruct.2016.06.029 ↗
6. Giampaoli, M., Terlizzi, V., Rossi, M., Chiappini, G., Munafo, P.: Mechanical performances of GFRP-steel specimens bonded with different epoxy adhesives, before and after the aging treatments. Compos. Struct. 171, 145–157 (2017). https://doi.org/10.1016/j.compstruct.2017.03.02010.1016/j.compstruct.2017.03.020 ↗
7. Ulger, T., Okeil, A.M.: Analysis of thin-walled steel beams retrofitted by bonding GFRP stiffeners: Numerical model and investigation of design parameters. Eng. Struct. 153, 166–179 (2017). https://doi.org/10.1016/j.engstruct.2017.10.01510.1016/j.engstruct.2017.10.015 ↗
8. Gebken, T., Kuhn, M., Demes, M., Muller, A., Droder, K.: Integral manufacturing of plastic-metal hybrids consisting of endless fiber reinforcement using injection molding. Mater. Today: Proc. 8(3), 804–811 (2019). https://doi.org/10.1016/j.matpr.2019.02.02210.1016/j.matpr.2019.02.022 ↗
9. Arenas, J.M., Alia, C., Narbon, J.J., Ocana, R.: Gonzalez.: Considerations for the industrial application of structural adhesive joints in the aluminium–composite material bonding. Compos. Part. B-Eng. 44(1), 417–423 (2013). https://doi.org/10.1016/j.compositesb.2012.04.02610.1016/j.compositesb.2012.04.026 ↗
10. Kabche, J.P., Caccese, V., Berube, K.A., Bragg., R.: Experimental characterization of hybrid composite-to-metal bolted joints under flexural loading. Compos. Part. B-Eng. 38(1), 66–78 (2007). https://doi.org/10.1016/j.compositesb.2006.03.01310.1016/j.compositesb.2006.03.013 ↗
11. Fortunato, A., Cuccolini, G., Ascari, A., Orazi, L., Campana, G., Tani, G.: Hybrid metal-plastic joining by means of laser. Int. J. Mater. Form. 3(1), 1131–1134 (2010). https://doi.org/10.1007/s12289-010-0971-110.1007/s12289-010-0971-1 ↗
12. Roesner, A., Scheik, S., Olowinsky, A., Gillner, A., Reisgen, U., Schleser, M.: Laser assisted joining of plastic metal hybrids. Phys. Procedia. 12, 370–377 (2011). https://doi.org/10.1016/j.phpro.2011.03.14610.1016/j.phpro.2011.03.146 ↗
13. Ramani, K., Moriarty, B.: Thermoplastic bonding to metals via injection molding for macro-composite manufacture. Polym. Eng. Sci. 38(5), 870–877 (1998). https://doi.org/10.1002/pen.1025310.1002/pen.10253 ↗
14. Zou, P., Zhang, H., Lei, M., Cheng, D.: Formation mechanism of direct laser welding joint between CFRTP and Ti-6Al-4V. Mater. Lett. 325, 132707 (2022). https://doi.org/10.1016/j.matlet.2022.13270710.1016/j.matlet.2022.132707 ↗
15. Katayama, S., Kawahito, Y.: Laser direct joining of metal and plastic. Scr. Mater. 59(12), 1247–1250 (2008). https://doi.org/10.1016/j.scriptamat.2008.08.02610.1016/j.scriptamat.2008.08.026 ↗
16. Balle, F., Wagner, G., Eifler, D.: Ultrasonic metal welding of aluminium sheets to carbon fibre reinforced thermoplastic composites. Adv. Eng. Mater. 11(1–2), 35–39 (2009). https://doi.org/10.1002/adem.20080027110.1002/adem.200800271 ↗
17. Huang, Y., Meng, X., Xie, Y., Li, J., Wan, L.: New technique of friction-based filling stacking joining for metal and polymer. Compos. Part. B-Eng 163, 217–223 (2019). https://doi.org/10.1016/j.compositesb.2018.11.05010.1016/j.compositesb.2018.11.050 ↗
18. Huang, Y., Meng, X., Xie, Y., Li, J., Wan, L.: Joining of carbon fiber reinforced thermoplastic and metal via friction stir welding with co-controlling shape and performance. Compos. Part. A-Appl S 112, 328–336 (2018). https://doi.org/10.1016/j.compositesa.2018.06.02710.1016/j.compositesa.2018.06.027 ↗
19. Amancio-Filho, S.T., Bueno, C., dos Santos, J.F., Huber, N., Hage, E.: On the feasibility of friction spot joining in magnesium/fiber-reinforced polymer composite hybrid structures. Mat. Sci. Eng. A-struct. 528(10), 3841–3848 (2011). https://doi.org/10.1016/j.msea.2011.01.08510.1016/j.msea.2011.01.085 ↗
20. Kimura, F., Kadoya, S., Kajihara., Y.: Effects of molding conditions on injection molded direct joining using a metal with nano-structured surface. Precis. Eng. 45, 203–208 (2016). https://doi.org/10.1016/j.precisioneng.2016.02.01310.1016/j.precisioneng.2016.02.013 ↗
21. Grujicic, M., Sellappan, V., Omar, M.A., Seyr, N., Obieglo, A., Erdmann, M., Holzleitner, J.: An overview of the polymer-to-metal direct-adhesion hybrid technologies for load-bearing automotive components. Mater. Process. Technol. 197(1), 363–373 (2008). https://doi.org/10.1016/j.jmatprotec.2007.06.05810.1016/j.jmatprotec.2007.06.058 ↗
22. Wang, S., Kimura, F., Zhao, S., Yamaguchi, E., Ito, Y., Kajihara, Y.: Influence of fluidity improver on metal-polymer direct joining via injection molding. Precis. Eng. 72, 620–626 (2021). https://doi.org/10.1016/j.precisioneng.2021.07.00110.1016/j.precisioneng.2021.07.001 ↗
23. Grujicic, M., Pandurangan, B., Bell, W.C., Daqaq, M., Ma, L., Seyr, N., Erdmann, M., Holzleitner, J.: A computational analysis and suitability assessment of cold-gas dynamic spraying of glass-fiber-reinforced poly-amide 6 for use in direct-adhesion polymer metal hybrid components. Appl. Surf. Sci. 254(7), 2136–2145 (2008). https://doi.org/10.1016/j.apsusc.2007.08.07710.1016/j.apsusc.2007.08.077 ↗
24. Li, X., Gong, N., Yang, C., Zeng, S., Fu, S., Zhang, K.: Aluminum/polypropylene composites produced through injection molding. Mater. Process. Technol. 255, 635–643 (2018). https://doi.org/10.1016/j.jmatprotec.2018.01.00810.1016/j.jmatprotec.2018.01.008 ↗
25. Chen, W., Kimura, F., Kajihara., Y.: Heat treatment induced strength improvement of the injection-molded joint between polymer and blasted steel. Mater. Lett. 333 (Suppl C). 133651 (2023). https://doi.org/10.1016/j.matlet.2022.13365110.1016/j.matlet.2022.133651 ↗
26. G. J., F. M., L.A. F., K. I., K. A: Laser structured surfaces for metal-plastic hybrid joined by injection molding. Laser Appl. 30(3), 032021–032021 (2018). https://doi.org/10.2351/1.503680310.2351/1.5036803 ↗
27. Bincheng, H., Lingyu, S., Lijun, L., Lin, Z., Yi, L., Jiangtao., C.: Experimental investigation of the strength of polymer-steel direct adhesion (PSDA) joints with micro-structures ablated by laser. J. Mater. Process. Tech. 249, 407–414 (2016). https://doi.org/10.1016/j.jmatprotec.2017.06.03110.1016/j.jmatprotec.2017.06.031 ↗
28. Sperandio, C., Bardon, J., Laachachi, A., Aubriet, H., Ruch, D.: Influence of plasma surface treatment on bond strength behaviour of an adhesively bonded aluminium-epoxy system. Int. J. Adhes. Adhes. 30(8), 720–728 (2010). https://doi.org/10.1016/j.ijadhadh.2010.07.00410.1016/j.ijadhadh.2010.07.004 ↗
29. Izadi, O., Mosaddegh, P., Silani, M., Dinari., M.: An experimental study on mechanical properties of a novel hybrid metal–polymer joining technology based on a reaction between isocyanate and hydroxyl groups. J. Manuf. Process. J 30, 217–225 (2017). https://doi.org/10.1016/j.jmapro.2017.09.02210.1016/j.jmapro.2017.09.022 ↗
30. Lv, X., Dong, W., Sheng, Y., Jin, J., Li, M., Zhao, Y., Wang, S.E.L.: Enhancing joint strength in direct-injection-molded PPS-Ti composite through plasma electrolytic oxidation coated interfaces. Surf. Coat. Tech 499, 131893 (2025). https://doi.org/10.1016/j.surfcoat.2025.13189310.1016/j.surfcoat.2025.131893 ↗
31. Kajihara, Y., Takeuchi, A., Kimura, F.: Direct joining between nano-textured metal and non-crystalline polymer via heating and cooling injection molding. CIRP Ann. 72(1), 473–476 (2023). https://doi.org/10.1016/j.cirp.2023.04.00410.1016/j.cirp.2023.04.004 ↗
32. Lobel, T., Kolesnikov, B., Scheffler, S., Stahl, A., Huhne, C.: Enhanced tensile strength of composite joints by using staple-like pins: Working principles and experimental validation. Compos. Struct. 106, 453–460 (2013). https://doi.org/10.1016/j.compstruct.2013.06.02010.1016/j.compstruct.2013.06.020 ↗
33. Teng, X., Xu, Y., Zhang, W., Liu, W., Yin, M.: Experimental investigations into delamination behavior of curved composite laminates reinforced by a pre-hole z-pinning (PHZ) method. Thin-Walled Struct. 188, 110822 (2023). https://doi.org/10.1016/j.tws.2023.11082210.1016/j.tws.2023.110822 ↗
34. Bagnato, T., Ravindran, A.R., Mirabedini, A., Ladani, R.B., Kandare, E., Orifici, A.C., Chang, P., Wang, J., Mouritz, A.P.: Superior interfacial toughening of hybrid metal-composite structural joints using 3D printed pins. Compos. Part. A-Appl S 168, 107479 (2023). https://doi.org/10.1016/j.compositesa.2023.10747910.1016/j.compositesa.2023.107479 ↗
35. Chen, H., Zi, X., Han, Y., Dong, J., Liu, S., Chen, C.: Microstructure and mechanical properties of additive manufactured W-Ni-Fe-Co composite produced by selective laser melting. Int. J. Refract. Met. H. 86, 105111 (2020). https://doi.org/10.1016/j.ijrmhm.2019.10511110.1016/j.ijrmhm.2019.105111 ↗
36. Chen, R., Zhao, Q., Li, M., Wang, S., Zhao, Y., Li, X., Wang, S.E.L.: Enhancing shear strength in hybrid metal-composite single-lap joints using Z-pins fabricated via fused filament fabrication. Thin-Walled Struct. 206, 112680 (2024). https://doi.org/10.1016/j.tws.2024.11268010.1016/j.tws.2024.112680 ↗
37. Yasaee, M., Lander, J.K., Allegri, G., Hallett, S.R.: Experimental characterisation of mixed mode traction–displacement relationships for a single carbon composite Z-pin. Compos. Sci. Technol. 94, 123–131 (2014). https://doi.org/10.1016/j.compscitech.2014.02.00110.1016/j.compscitech.2014.02.001 ↗
38. Oliveira, G.H.M., Sciuti, V.F., Canto, R.B., Arneitz, S., Minkowitz, L., Filho, S.T.A., Canto, L.B.: Additive manufacturing of surface structured metal parts for high strength lightweight injection overmolded polymer-metal hybrid joints. Int. J. Adhes. 141, 104045–104045 (2025). https://doi.org/10.1016/j.Ijadhadh.2025.10404510.1016/j.Ijadhadh.2025.104045 ↗
39. Nguyen, A.T.T., Brandt, M., Orifici, A.C., Feih, S.: Hierarchical surface features for improved bonding and fracture toughness of metal–metal and metal–composite bonded joints. Int. J. Adhes. Adhes. 66, 81–92 (2016). https://doi.org/10.1016/j.ijadhadh.2015.12.00510.1016/j.ijadhadh.2015.12.005 ↗
40. Nguyen, A.T.T., Amarasinghe, C.K., Brandt, M., Feih, S., Orifici, A.C.: Loading, support and geometry effects for pin-reinforced hybrid metal-composite joints. Compos. Part. A-Appl S 98, 192–206 (2017). https://doi.org/10.1016/j.compositesa.2017.03.01910.1016/j.compositesa.2017.03.019 ↗
41. Nguyen, A.T.T., Pichitdej, N., Brandt, M., Feih, S., Orifici, A.C.: Failure modelling and characterisation for pin-reinforced metal-composite joints. Compos. Struct. 188, 185–196 (2018). https://doi.org/10.1016/j.compstruct.2017.12.04310.1016/j.compstruct.2017.12.043 ↗
42. Carlton, H.D., Klein, K.D., Elmer, J.W.: Evolution of microstructure and mechanical properties of selective laser melted Ti-5Al-5V-5Mo-3Cr after heat treatments. Sci. Technol. Weld. Join. 24(5), 465–473 (2019). https://doi.org/10.1080/13621718.2019.159458910.1080/13621718.2019.1594589 ↗
43. Zhang, W., Wang, L., Feng, Z.: Chen.: Research progress on selective laser melting (SLM) of magnesium alloys: A review. Optik. 207, 163842 (2020). https://doi.org/10.1016/j.ijleo.2019.16384210.1016/j.ijleo.2019.163842 ↗
44. Thijs, L., Verhaeghe, F., Craeghs, T., Van Humbeeck, J., Kruth., J.-P.: A study of the micro structural evolution during selective laser melting of Ti-6Al-4V. Acta Mater. 58(9), 3303–3312 (2010). https://doi.org/10.1016/j.actamat.2010.02.00410.1016/j.actamat.2010.02.004 ↗
45. Gomez Gras, G., Jerez Mesa, R., Travieso Rodriguez, J.A.: Lluma Fuentes.: Fatigue performance of fused filament fabrication PLA specimens. Mater. Des. 140, 278–285 (2018). https://doi.org/10.1016/j.matdes.2017.11.07210.1016/j.matdes.2017.11.072 ↗
46. Kuznetsov, V.E., Solonin, A.N., Urzhumtsev, O.D., Schilling, R., Tavitov, A.G.: Strength of PLA components fabricated with fused deposition technology using a desktop 3D printer as a function of geometrical parameters of the process. Polymers 10(3), 313 (2018). https://doi.org/10.3390/polym1003031310.3390/polym10030313 ↗
47. Caminero, M.A., Romero Gutierrez, A., Chacon, J.M., Garcia-Plaza, E., Nunez, P.J.: Effects of fused filament fabrication parameters on the manufacturing of 316L stainless-steel components: Geometric and mechanical properties. Rapid Prototyp. J. 28(10), 2004–2026 (2022). https://doi.org/10.1108/RPJ-01-2022-002310.1108/RPJ-01-2022-0023 ↗
48. Garcia Plaza, E., Nunez Lopez, P.J., Caminero Torija, M.A., Chacon Munoz, J.M.: Analysis of PLA geometric properties processed by FFF additive manufacturing: Effects of process parameters and Plate-Extruder precision motion. Polymers 11(10), 1581 (2019). https://doi.org/10.3390/polym1110158110.3390/polym11101581 ↗
49. Zhao, Q., Chen, R., Wang, S., Hao, W., Dong, W., Li, X., Wang, L.: Utilization of fused deposition modeling in the fabrication of lattice structural Al2O3 ceramics. Ceram. Int. 50(19), 35193–35202 (2024). https://doi.org/10.1016/j.ceramint.2024.06.32810.1016/j.ceramint.2024.06.328 ↗
50. Chen, R., Zhao, Q., Wang, S., Hu, Z., Dong, W., Li, X., Wang, S.E.L.: Effects of printing parameters on the properties of 316L stainless steel fabricated by fused filament fabrication. Rapid Prototyp. J. 31(5), 968–980 (2025). https://doi.org/10.1108/RPJ-08-2024-035610.1108/RPJ-08-2024-0356 ↗
51. Mouritz, A.P.: Review of z-pinned composite laminates. Compos. Part. A. 38(12), 2383–2397 (2007). https://doi.org/10.1016/j.compositesa.2007.08.01610.1016/j.compositesa.2007.08.016 ↗
52. Ozcelik, B., Erzurumlu, T.: Comparison of the warpage optimization in the plastic injection molding using ANOVA, neural network model and genetic algorithm. J. Mater. Process. Tech 171(3), 437–445 (2006). https://doi.org/10.1016/j.jmatprotec.2005.04.12010.1016/j.jmatprotec.2005.04.120 ↗
53. Wang, C., Mai, W., Shi, Q., Liu, Z., Pan, Q.: Effect of printing parameters on mechanical properties and dimensional accuracy of 316l stainless steel fabricated by fused filament fabrication. J. Mater. Eng. Perform. 33(21), 11781–11793 (2024). https://doi.org/10.1007/s11665-023-08848-810.1007/s11665-023-08848-8 ↗
54. Grujicic, M., Sellappan, V., Omar, M.A., Seyr, N., Obieglo, A., Erdmann, M., Holzleitner, J.: An overview of the polymer-to-metal direct-adhesion hybrid technologies for load-bearing automotive components. J. Mater. Process. Tech 197(1), 363–373 (2008). https://doi.org/10.1016/j.jmatprotec.2007.06.05810.1016/j.jmatprotec.2007.06.058 ↗
55. Lin, Y., Li, H., Wang, Q., Gong, Z.: Effect of plasma surface treatment of aluminum alloy sheet on the properties of Al/Gf/PP laminates. Appl. Surf. Sci. 507, 145062 (2020). https://doi.org/10.1016/j.apsusc.2019.14506210.1016/j.apsusc.2019.145062 ↗
56. Ye, C., Chen, X., Wang, L., Peng, W., Zhu, W., Dong, W., Wang, B., Li, S.E.X.: Highly enhanced joint strength of direct-injection-moulded polyphenylene sulphide-magnesium composite by PEO coated interface. Surf. Coat. Tech. 404, 126565 (2020). https://doi.org/10.1016/j.surfcoat.2020.12656510.1016/j.surfcoat.2020.126565 ↗
57. Liu, D., Zhou, F.: The polymer-metal interactive behavior in polyphenylene sulfide/aluminium hetero interface in nano injection molding. Compos. Interfaces. 27(3), 277–288 (2020). https://doi.org/10.1080/09276440.2019.162613810.1080/09276440.2019.1626138 ↗
58. Murashima, T., Taniguchi., T.: Multiscale simulation of history-dependent flow in entangled polymer melts. Epl. 96(1), 18002 (2011). https://doi.org/10.1209/0295-5075/96/1800210.1209/0295-5075/96/18002 ↗
59. Wang, Y., Li, X., Shuai, S., Zhang, H., Liu, N., Wang, Z., Jin, L., Zheng, A.: Application of rheology to hot melt extrusion: Theory and practice. Int. J. Pharm. 680, 125742 (2025). https://doi.org/10.1016/j.ijpharm.2025.12574210.1016/j.ijpharm.2025.125742 ↗
60. Yong, L., Kaiyu, J.: Study on rheological properties of in-mold co-injection self-reinforced polymer melt. Polym. Test. 93, 106910 (2021). https://doi.org/10.1016/j.polymertesting.2020.10691010.1016/j.polymertesting.2020.106910 ↗
61. Dong, X.E.A., Li, Y.Email Author, Zhang, X., Xiao, J., Li, W., View: Correspondence.: Performance of polymer composite single lap joints reinforced by Z-pin. Acta Aeronaut. 35(5), 1302–1310 (2014). https://doi.org/10.7527/s1000-6893.2013.039810.7527/s1000-6893.2013.0398 ↗