The recent increases in CFRP usage in primary aerospace structures, together with the relentless drive for cost saving and improved efficiency have introduced new challenges for managing areas of high-load input, particularly when joining between composite and metallic parts. In order to move from the relative security of traditional bolted connections towards the efficient load transfer offered by adhesive joints, whilst preserving graceful failure characteristics, Airbus have been investigating Hybrid Penetrative Reinforcement (HYPER) as an alternative joining method. This method provides the potential for integrally cured hybrid metallic/composite parts, providing excellent mechanical properties as well as the security and toughness of a geometrically generated mechanical connection. A significant amount of testing has already been performed to validate the performance benefits of this type of joint, while developments in advanced metallic manufacturing have provided a cost effective means of interface feature fabrication.
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