Experimental Study of Single-Lap, Hybrid Joints, Made of 3D Printed Polymer and Aluminium Adherends

This paper presents the results of an experimental study into single-lap joints. One part of the joint was made as a 3D printed polymer and had cylindrical tenons, while the other part was made of an aluminium flat bar having mortises whose diameter and distribution corresponded to the polymer tenons. In addition to the mechanical joint, a layer of double-sided VHB (Very High Bond) adhesive tape was also placed in the lap, thus creating a hybrid joint. In total, 80 specimens were made, which were divided into four groups: A—specimens with one tenon of different diameters, B—specimens with different number of tenons of the same diameter, C—specimens characterised by multi-stage operation and R—reference specimens, connected only by double-sided adhesive tape. The joints were subjected to uniaxial tensile tests. The force–displacement characteristics obtained and the energy required, up to the point of the failure of the joints, have been analysed in this paper. The four and six-stage joints designed can significantly increase the safety of the structures in which they will be used.