Hybrid CFRP/titanium bolted joints: Performance assessment and application to a spacecraft payload adaptor

Abstract This paper presents an experimental investigation of the mechanical response and the industrial manufacturability of CFRP–titanium hybrid laminates using the example of a spacecraft payload adaptor. The local hybridization with metal within a bolted joint region of composite laminates is proven to be an effective method of increasing the mechanical joint efficiency of highly loaded bolted joints. High-strength titanium foils are locally embedded into the composite laminate by means of ply substitution techniques, thus avoiding any local laminate thickening and providing for a local laminate with high bearing and shear capabilities. An extensive sample and component test program has been performed evaluating the impact of different design parameters and load conditions. The verification of the hybrid technique’s processability, inspectability and compatibility with a standard industrial fibre placement process has been successfully demonstrated through the manufacturing of a spacecraft payload adaptor featuring diverse applications of the hybridization technique.