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<p>Hybrid joining of titanium alloys and carbon fiber-reinforced thermoplastic composites (CFRTP) is essential for lightweight aerospace applications but limited by interfacial weaknesses and inadequate monitoring. This work proposes an ultrasonic CFRTP-rivet-based hybrid riveting–welding strategy for joining continuous carbon fiber-reinforced polycarbonate (CF/PC) composites and Ti-6Al-4&#xa0;V (TC4) titanium alloy. The method integrates hot riveting of a same-material CF/PC rivet with dissimilar-interface ultrasonic welding within a single joining cycle, while surface grooving and anodic oxidation of TC4 are introduced as supporting interface-engineering measures to strengthen interfacial bonding. This approach improved the joint shear strength by 11.08%, and increased the cross-lap tensile strength by 128.6% compared to the direct weld. Microscopic analysis revealed the joint formation to be governed mainly by macro-/micro-mechanical interlocking together with possible interfacial chemical interaction. Furthermore, an in-situ interfacial resistance monitoring method was implemented throughout both the welding process and subsequent mechanical loading. Distinct resistance stages during welding corresponded to interfacial evolution phases, with the final joint resistance further used to establish a preliminary prediction model for joint strength. During single lap tensile-shear, cyclic loading, and cross lap tensile tests, real-time resistance changes reflected the progressive evolution of internal damage, indicating the potential of this method for structural health monitoring. As a metal-fastener-free and adhesive-independent solution, this integrated approach of joint reinforcement and resistance-based monitoring offers simplified processing, inherent compatibility with automated production, and a cost-effective, non-destructive quality assessment strategy for sustainable, advanced lightweight manufacturing.</p>

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Interfacial joining and in-situ resistance monitoring in ultrasonic hybrid riveting–welding of CFRTP and titanium alloy

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年7月9日

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  • Yu-Yao Ren,
  • Bin Han,
  • Qi-Yuan Yan,
  • Jian Yang,
  • Yu-Fan Wei,
  • Qi Zhang

摘要

Hybrid joining of titanium alloys and carbon fiber-reinforced thermoplastic composites (CFRTP) is essential for lightweight aerospace applications but limited by interfacial weaknesses and inadequate monitoring. This work proposes an ultrasonic CFRTP-rivet-based hybrid riveting–welding strategy for joining continuous carbon fiber-reinforced polycarbonate (CF/PC) composites and Ti-6Al-4 V (TC4) titanium alloy. The method integrates hot riveting of a same-material CF/PC rivet with dissimilar-interface ultrasonic welding within a single joining cycle, while surface grooving and anodic oxidation of TC4 are introduced as supporting interface-engineering measures to strengthen interfacial bonding. This approach improved the joint shear strength by 11.08%, and increased the cross-lap tensile strength by 128.6% compared to the direct weld. Microscopic analysis revealed the joint formation to be governed mainly by macro-/micro-mechanical interlocking together with possible interfacial chemical interaction. Furthermore, an in-situ interfacial resistance monitoring method was implemented throughout both the welding process and subsequent mechanical loading. Distinct resistance stages during welding corresponded to interfacial evolution phases, with the final joint resistance further used to establish a preliminary prediction model for joint strength. During single lap tensile-shear, cyclic loading, and cross lap tensile tests, real-time resistance changes reflected the progressive evolution of internal damage, indicating the potential of this method for structural health monitoring. As a metal-fastener-free and adhesive-independent solution, this integrated approach of joint reinforcement and resistance-based monitoring offers simplified processing, inherent compatibility with automated production, and a cost-effective, non-destructive quality assessment strategy for sustainable, advanced lightweight manufacturing.