LAUSR

Abstract Wire mesh interlayers are introduced to fabricate high interface strength metal-polymer-metal sandwich panels. While resistance welding is used to join metal sheets to wire mesh at predesignated spots, vacuum hot pressing is used to infuse polymer into the wire mesh. Peel strength for fabricated sandwich panels is seen to be around 300% higher than that for adhesive joints reported in literature. Since, interface strength is achieved from welding and mechanical interlocking, it does not degrade in presence of moisture. Uni-axial tensile tests are used to characterize strength and elongation of individual layers and fabricated sandwich panels. Interface strength is characterized using peel and double lap shear tests. V-bending and stretch forming experiments are used to demonstrate formability of the developed sandwich panels. The presented method is an attractive alternative to use of adhesives for joining of metals to polymers.