# Conceptual Design of a Hybrid Composite to Metal Joint for Naval Vessels Applications

## TL;DR

This paper introduces a new hybrid composite-metal joint design for naval vessels that is cost-effective and avoids the need for complex welding.

## Contribution

A novel hybrid composite-metal joint design using friction stir-formed studs and resin infusion for naval applications is proposed.

## Key findings

- The hybrid joint design was validated through simulation and experimental testing.
- The joint's performance was evaluated in terms of force displacement and failure modes.
- The design offers a cost-effective alternative to traditional welding methods.

## Abstract

This paper describes the development of a new hybrid composite for the metal joints of aluminium and glass fibre composite adherents. The aluminium adherend is manufactured using friction stir-formed studs that are inserted into the composite adherend in the through-thickness direction during the composite manufacturing process, where the dry fibres are displaced to accommodate the studs before the resin infusion process. The materials used were AA6082-T6 aluminium and plain-woven E-glass fabric reinforced epoxy, with primary applications in naval vessels. This joining approach offers a cost-effective solution that does not require complicated onsite welding. The joint design was developed based on a simulation test program with finite element analysis, followed by experimental characterisation and validation. The design solution was analysed in terms of the force displacement response, sequence of load transfer, and characterisation of the joint failure modes.