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<p>This work examines the joining performance of metal-polymer composite single-lap joints (SLJs) enhanced with 316&#xa0;L stainless steel Z-pins manufactured through fused filament fabrication (FFF). The Z-pin arrays and steel substrates were co-printed using FFF, and then subjected to debinding and sintering processes. The resulting structure was subsequently combined with polyphenylene sulfide (PPS) through an injection molding direct joining (IMDJ) process to create durable 316&#xa0;L-PPS composite SLJs. The results show that incorporating FFF-fabricated Z-pins significantly enhance the joining performance of metal-polymer SLJs. A detailed investigation into the effects of pinning density and Z-pin alignment on polymer melt behavior and joint performance revealed that higher pinning densities and vertically aligned Z-pins (90° angle) resulted in superior joint strength. This configuration enhanced PPS melt flow, minimized interfacial defects, and achieved the highest shear strength—improving by up to 113.1% compared to unreinforced joints. The improved mechanical response is primarily due to the Z-pins’ ability to dissipate energy through mechanisms such as interfacial sliding and localized deformation, which hinder crack initiation and growth. This study presents a distinctive strategy for engineering metal-polymer composite joints, enabling the fabrication of multifunctional hybrid structures with enhanced performance.</p>

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Shear Strength Enhancement of Injection-Molded Metal-Polymer Composite Joints Using Z-Pins Manufactured Through Fused Filament Fabrication

  • 期刊论文

  • 发表日期：

    2025年12月4日

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  • Run Chen,
  • Xin Lv,
  • Qixin Zhao,
  • Mengjia Li,
  • Yuan Zhao,
  • Sisi Wang,
  • Shiju E,
  • Linlin Wang

摘要

This work examines the joining performance of metal-polymer composite single-lap joints (SLJs) enhanced with 316 L stainless steel Z-pins manufactured through fused filament fabrication (FFF). The Z-pin arrays and steel substrates were co-printed using FFF, and then subjected to debinding and sintering processes. The resulting structure was subsequently combined with polyphenylene sulfide (PPS) through an injection molding direct joining (IMDJ) process to create durable 316 L-PPS composite SLJs. The results show that incorporating FFF-fabricated Z-pins significantly enhance the joining performance of metal-polymer SLJs. A detailed investigation into the effects of pinning density and Z-pin alignment on polymer melt behavior and joint performance revealed that higher pinning densities and vertically aligned Z-pins (90° angle) resulted in superior joint strength. This configuration enhanced PPS melt flow, minimized interfacial defects, and achieved the highest shear strength—improving by up to 113.1% compared to unreinforced joints. The improved mechanical response is primarily due to the Z-pins’ ability to dissipate energy through mechanisms such as interfacial sliding and localized deformation, which hinder crack initiation and growth. This study presents a distinctive strategy for engineering metal-polymer composite joints, enabling the fabrication of multifunctional hybrid structures with enhanced performance.