Joint Strength Determination by a Resistance-Based Sensor in Metal-Polymer Joining by Hydraulic Expansion

The joining of metallic and thermoplastic components offers the possibility of weight reduction with a simultaneous increase in functionality, whereby the determination of the joint strength is of special interest. In the context of this study, the use of resistance-based sensors for joining by hydraulic expansion of tubes made of aluminum and polycarbonate was investigated. The contact pressure, determined in time and spatial resolution, was used to determine the axial load transferability and compared with the common methodology of the pull-out test. By using this measurement method, it was possible to determine the influence of the force- and form-fit onto the joint strength.