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Hybrid (Composite to metal) Joining

Webinars 24 January 2019

It is a well-known fact that continuous fibre reinforced polymer (FRP) composite systems constitute an extremely versatile group of materials due to their high strength to mass ratio, anisotropic properties and opportunities for design freedom. In the vast majority of cases, the outstanding properties that composite materials offer (high strength, low weight, design flexibility, etc.) are only truly realised when composites are combined with other materials, such as metals. Traditional joining methods, such as adhesive bonding or fastening, adopt a ‘black metal’ approach where the joint assumes a simple planar configuration. This results in a compromise; either composite damage has to be tolerated (fastener holes) or the loading capacity is limited by the strength of the matrix resin, either at the composite surface or between the first or second plies. Over the past four decades, a large number of approaches have been taken to address this limitation, most of them by adopting some type of through-thickness reinforcement/enhancement to enable loads to be spread more evenly into the bulk of the composite; a graded hybrid joint.

TWI has been serving its Members by providing solutions to hybrid joining problems for over 25 years, and has made significant contributions to the development of new technologies. After 25 years of reviewing hybrid joining there would appear to be no shortage of ideas to address the challenge of joining composites to metals, although very few appear to have successfully made the transition from an academic concept into a mature joining technology used extensively in many applications and industries.

This FREE webinar aims to present both a historical and technological overview of the various hybrid joining approaches that have been proposed, dating back to the 1970s, and tries to simplify the wide variety of techniques by condensing them into seven fundamental categories. This webinar will be of interest to engineers who work with different materials and who strive to optimise the structural integrity of their products; being confident to use the right materials in the right place, and ensuring they all stay together. 

Time of Webinar: 3pm - 4pm (GMT)

Meet the team

Dr. Chris Worrall

Principal Project Leader – Adhesives, Composites and Sealants

Chris Worrall is a principal project leader responsible for composites joining, manufacture, processing and testing. He is a metallurgy and materials science graduate, with a PhD in the impact of composite sandwich materials. Chris has spent ten years in Japan working in the automotive, aerospace, renewable energy and rail transport industries.

Before leaving the UK, he worked in a research laboratory on the processing of novel thermoplastic composite materials, improving the toughness of composites, and developing test methods for composite materials. His 30 years of composites experience covers composite-to-metal joining, dielectric characterisation, mechanical testing of composite materials, finite element analysis, design of composite structures, and manufacturing technology for composite materials. He successfully led TWI’s technical, exploitation and dissemination activities in the FP7 FibreChain project, which won a JEC innovation award. Chris is part of the Surflow™ team at TWI that recently won the Composites UK Innovation award.

For more information please email:


contactus@twi.co.uk