Synergy of Steel and Satin: A Review of Metallic and Carbon Fiber Composite Materials in Modern Automotive Manufacturing
DOI:
https://doi.org/10.64229/33dp4a84Keywords:
Multi-material Design, Carbon Fiber Reinforced Polymer (CFRP), High-Strength Steel (HSS), Hybrid Joining, Mechanical Fastening, Thermoplastic CompositesAbstract
The automotive industry is undergoing a profound transformation driven by the imperatives of weight reduction, enhanced safety, and improved fuel efficiency or extended range for electric vehicles. This paradigm shift has necessitated a move away from traditional, monolithic material strategies towards sophisticated multi-material design. In this context, the combination of metallic materials, primarily aluminum and high-strength steel (HSS), with advanced carbon fiber reinforced polymers (CFRPs) has emerged as a leading frontier. Metals offer well-understood behavior, excellent ductility, and cost-effectiveness, while CFRPs provide an unparalleled specific strength and stiffness. However, their integration presents significant challenges, particularly in joining and long-term durability. This review article provides a comprehensive analysis of the current state-of-the-art in the application and fusion of these disparate material systems. It begins by delineating the roles and evolving applications of key metallic alloys and CFRPs in automotive body-in-white (BIW), chassis, and interior components. The core of the review is dedicated to a critical examination of hybrid joining technologies, including adhesive bonding, mechanical fastening, and their hybrids, with a focused discussion on the emerging promise of thermoplastic-based fusion bonding. The interplay between material properties, manufacturing processes, and joint performance is thoroughly explored. Furthermore, the article presents case studies of production vehicles that have successfully implemented metal-CFRP hybrid structures, analyzing their design philosophies and performance outcomes. Finally, the paper identifies key technical hurdles, such as galvanic corrosion and recyclability, and discusses the ongoing research directions aimed at overcoming them. The central thesis is that the successful fusion of metals and CFRPs is not merely a joining challenge but a systems-level integration problem encompassing materials science, manufacturing engineering, and structural design, which is pivotal for the next generation of high-performance, efficient vehicles.
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