Influence of bionic texture on the mechanical properties of 6061Al/CFRTP laser joints

Joining carbon fiber reinforced thermoplastic composites (CFRTP) with metals is a significant challenge for lightweighting in the automotive sector. The lower strength of hybrid joints limits their applications in the relevant fields. In this study, three distinct surface textures were applied to 6061 aluminum alloy (6061Al), including a traditional groove texture and two novel bionic textures (shark skin and fish scale), to enhance the strength of the hybrid joint between the materials. The impact of these textures on the mechanical properties of 6061Al/CFRTP hybrid joints was investigated through experimental methods and finite element simulations. The results indicated that the stress distribution at the interface of the bionic textured samples was more uniform, reducing stress concentration at the interface. Furthermore, the hybrid joint strength was improved as the bionic texture hindered crack initiation and propagation and facilitated crack deflection. Compared to the untextured samples, the fish scale textured samples exhibited the highest strength, which increased by 431.3 % relative to the untextured samples.