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A novel composite-composite joining technology based on metal pins oriented in through thickness direction of the composites is presented. A defined pin geometry, which is capable of establishing a through-thickness form-fit connection between composites and the metal reinforcement, is created on thin metal sheets in an automated pin production process. Based on numerical simulations of the fracture of unreinforced single lap shear (SLS) composite specimens, optimum locations for the pin reinforcement were found. Tests on reinforced SLS specimens proved that an enhanced damage tolerance can be achieved by the use of cold metal transfer welded pins (CMT pins) as through-the-thickness reinforcement of the joint area. This paper investigates the mechanisms responsible for the load transfer and failure of such through-the-thickness reinforced composite-composite joints during monotonic loading.

This research paper presents a new possibility for the connection of metal sheets and fibre reinforced plastics (FRPs) through a cold metal transfer welding process. Small metal projections (pins) are welded onto metal surfaces by introduction of additional filler wire. These provide the possibility for building up a fixation with composites through fibre-friendly form-closure and co-curing. Results of tensile loaded double-lap shear geometries are presented for three types of pin geometries. The hybrid joints will be characterized and compared in terms of maximum reaction force and failure history. Joints with cylindrical and spiky pins inside show a certain load transfer capability, where ultimate bearing load and post failure behaviour have a high dependence on the quality of the co-cured adhesive bonding and the bending characteristics of the pins. Joints with spherical ending pins show twice as high ultimate bearing loads at a much more distinctive joint expansion.

In this paper, a lightweight ironless axial flux permanent magnet drive concept is presented. The in-wheel hub motor has a high torque to weight ratio and achieves a high efficiency, which extends the operation range of battery powered vehicles. The steps from preliminary design to manufacturing of the components are described. The paper includes Finite Element Analyses in different physical domains.

At present, enhancement of hybrid metal joints for tensile pull-out load through overlap surfaces with a macro-scale roughness is one scope of research. The macro-scale roughness is established through the modified arc-welding process, called “cold metal transfer pin” (CMT-pin), which enables repetitive manufacturing of arrays of metal reinforcements (pins) on parent metal surfaces.Hybrid metal joints between parent steel sleeves and cast aluminium alloy have been investigated. Joint surfaces of parent steel sleeves, which have cylindrical cross-sections, are modified by cylinder and ballhead pins. Cast metal joints were tested under uniaxial tensile loading. At the same time, their load transfer behaviour was determined. Results of tensile tests of hybrid metal joints with different kinds of pins, as well as with different amounts of pins are presented. Comparisons with reference joints without pins or with steel sleeves containing a harmonious triangular polygon cross-section ("P3G") and endings with an enlarged diameter are carried out.The results show an enhanced load transfer performance in the case of hybrid metal joints with pins, as well as enhanced performance measures compared to reference joints. It is also shown that the pin quantity has a major impact on the ultimate joint strength and the irreversible energy absorption density. The use of a certain quantity of pins leads to a change of the failure shape of the joints, which includes steel sleeve pull-out and pin shear to rupture of the cast aluminium.