Microstructure and Mechanical Performance of Additively Manufactured Aluminum 2024-T3/Acrylonitrile Butadiene Styrene Hybrid Joints Using an AddJoining Technique

AddJoining is an emerging technique that combines the principles of the joining method and additive manufacturing. This technology is an alternative method to produce metal–polymer (composite) structures. Its viability was demonstrated for the material combination composed of aluminum 2024-T3 and acrylonitrile butadiene styrene to form hybrid joints. The influence of the isolated process parameters was performed using the one-factor-at-a-time approach, and analyses of variance were used for statistical analysis. The mechanical performance of single-lap joints varied from 910 ± 59 N to 1686 ± 39 N. The mechanical performance thus obtained with the optimized joining parameters was 1686 ± 39 N, which failed by the net-tension failure mode with a failure pattern along the 45° bonding line. The microstructure of the joints and the fracture morphology of the specimens were studied using optical microscopy and scanning electron microscopy. From the microstructure point of view, proper mechanical interlocking was achieved between the coated metal substrate and 3D-printed polymer. This investigation can be used as a base for further improvements on the mechanical performance of AddJoining hybrid-layered applications.