Recent Advances in Joining Technologies for Dissimilar Materials between Resin-based Composites and Lightweight Metals

YANG Bolin; FU Mengchun; LIN Panpan; LIN Tiesong; HE Peng

doi:10.3969/j.issn.1674-6457.2026.06.001

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (6) : 1-15. DOI: 10.3969/j.issn.1674-6457.2026.06.001

Joining of New Materials and Dissimilar Materials

Recent Advances in Joining Technologies for Dissimilar Materials between Resin-based Composites and Lightweight Metals

YANG Bolin, FU Mengchun, LIN Panpan, LIN Tiesong, HE Peng

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Abstract

Driven by the growing demand for lightweight and high-performance structural materials in sectors including aerospace, new energy vehicles and high-end equipment manufacturing, heterogeneous structures consisting of resin-based composites and metals have attracted extensive research attention, as such structures integrate the respective superiorities of constituent materials and deliver outstanding lightweight performance alongside high specific strength. Nevertheless, pronounced discrepancies in physical properties, surface energy and deformation behaviors between the two material categories readily trigger adverse issues at bonding interfaces such as concentrated residual stress, interfacial debonding and thermal damage, compromising the service reliability of bonded joints. The work aims to review the research status on joining technologies between resin-based composites and typical lightweight metals (aluminum alloy, titanium alloy, magnesium alloy and high- strength steel), covering four mainstream joining categories: mechanical fastening, adhesive bonding, advanced welding (high-energy beam welding and solid-state welding) and hybrid joining. Fundamental principles, technological evolution, interfacial regulation approaches and mechanical characteristics of joints for each joining method are elaborated, with particular emphasis laid on interfacial formation mechanisms and interfacial reinforcement strategies. Finally, the prospective development trends of composite-metal joining technologies are outlined.

Key words

resin-based composites / lightweight metal / heterogeneous bonding / interfacial bonding / interface enhancement strategy

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YANG Bolin, FU Mengchun, LIN Panpan, LIN Tiesong, HE Peng. Recent Advances in Joining Technologies for Dissimilar Materials between Resin-based Composites and Lightweight Metals[J]. Journal of Netshape Forming Engineering. 2026, 18(6): 1-15 https://doi.org/10.3969/j.issn.1674-6457.2026.06.001

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