Baptista, R. J. S.Pragana, JoãoBragança, IvoSilva, CarlosAlves, LuísMartins, Paulo2020-05BAPTISTA, R. J. S.; [et al] – Joining aluminium profiles to composite sheets by additive manufacturing and forming. Journal of Materials Processing Technology. ISSN 0924-0136. Vol. 279 (2020), pp. 1-80924-0136http://hdl.handle.net/10400.21/12709This paper explores the application of the 'mortise-and-tenon' concept for joining hollow section aluminium profiles to composite strips or sheets. Wire arc additive manufacturing is combined with joining by forming to fabricate the tenons and to obtain the mechanical interlocking with the mortises available in the strips (or sheets). The workability limits are established by means of an analytical model that combines plastic deformation, instability and fracture. Experimental and finite element modelling are utilized to develop the overall joining process and to validate the round 'mortise-and-tenon' design resulting from the analytical model. Pull-out and shear destructive tests are carried out to evaluate the overall strength of the joints and results allow concluding that the new joints can easily and effectively replace existing solutions based on welding, fastening or adhesive bonding. The proposed joining process also circumvents the need to design extra fixing and interlocking features in low cost hollow section aluminium profiles for easy assembling.engWire arc additive manufacturingJoining by formingAluminium profilesComposite strips and sheetsExperimentationFinite element methodjournal article10.1016/j.jmatprotec.2019.1165871873-4774