This paper compares selected novel methods for the mechanical joining of thermoplastic composites and metal sheets, with emphasis on Flow Drill Joining (FDJ), Thermoclinching, Hotclinching, and Insert Clinching. The study focuses on the joining principles, technological characteristics, and the effect of each process on the local structure of the composite, particularly fibre reorientation, fibre damage, and the formation of a mechanical interlock. Based on the reviewed literature, Hotclinching offers a favourable balance between joint strength and production efficiency, while Thermoclinching enables a reliable form-lock at the cost of greater process complexity. Insert Clinching is advantageous because it reduces damage to the composite during the final joining stage, whereas FDJ appears promising due to its element-free principle and minimal disturbance of the fibre architecture. The comparison shows that the selection of a suitable joining method depends mainly on the required load-bearing capacity, process complexity, and the acceptable level of structural modification in the composite.
thermoplastic composites; metal sheets; mechanical joining; flow drill joining; thermoclinching; hotclinching; insert clinching; hybrid joints; fibre reorientation; form-locking joints.
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