Fatigue Performance of Metal–Composite Friction Spot Joints

Friction spot joining is an alternative technique for joining metals with polymers and composites. This study investigated the fatigue performance of aluminum alloy 2024/carbon-fiber-reinforced poly(phenylene sulfide) joints that were produced with friction spot joining. The surface of the aluminum was pre-treated using various surface treatment methods. The joined specimens were tested under dynamic loading using a load ratio of R = 0.1 and a frequency of 5 Hz. The tests were performed at different percentages of the lap shear strength of the joint. Three models—exponential, power law, and wear-out—were used to statistically analyze the fatigue life of the joints and to draw the stress–life (S–N) curves. The joints showed an infinite life of 25–35% of their quasi-static strength at 10(6) cycles. The joints surpassing 10(6) cycles were subsequently tested under quasi-static loading, showing no considerable reduction compared to their initial lap shear strength.