Pragana, JoãoContreiras, Tomás R. M.Bragança, IvoSilva, CarlosAlves, LuísMartins, Paulo2020-04-222020-04-222019-08PRAGANA, João P. M.; [et al] – Joining by forming of metal-polymer sandwich composite panels. Proceedings of the Institution of Mechanical Engineers Part-B: Journal of Engineering Manufacture. ISSN 0954-4054. Vol. 233, N.º 10 (2019), pp. 2089-20980954-4054http://hdl.handle.net/10400.21/11488Este trabalho foi financiado pelo Concurso Anual para Projetos de Investigação, Desenvolvimento, Inovação e Criação Artística (IDI&CA) 2016 do Instituto Politécnico de Lisboa. Código de referência IPL/2016/CompSBJ_ISELThis article presents new joining-by-forming processes to assemble longitudinally two metal-polymer sandwich composite panels perpendicular to one another. Process design draws from an earlier development of the authors for metal sheets to new concepts based on the combination of sheet-bulk forming with mortise-and-tenon joints. Selected examples obtained from experimentation and finite element modelling give support to the presentation. A new three-stage joining by the forming process is capable of producing mechanically locked joints with larger and stiffer flat-shaped heads than those fabricated by alternative single- or two-stage solutions. Failure in the new three-stage joining by the forming process is found to take place by cracking instead of disassembling after unbending the flat-shaped head of the joint back to its original shape. The required forming forces to produce the new metal-polymer joints are below 15 kN, allowing them to be an effective, easy-to-implement alternative to existing solutions based on adhesive bonding, welding and mechanical fastening.engJoining by formingSandwich compositesExperimentationFinite element methodDestructive testingjournal article10.1177/0954405418815386