本研究針對碳纖維複合材料（CFRP）與鋁合金異材之混合式單搭接接頭，探討不同纖維鋪層方向與接合設計對其機械性能之影響。實驗設計包含四種自穿鉚接（Self-Piercing Riveting, SPR）接頭形式：傳統型（R-SPR）、預浸布後固化型（PC-SPR）、預鑽孔型（PH-SPR）、預鑽孔並預浸布後固化型（PHPC-SPR），並搭配兩種CFRP鋪層方式（[0°/90°/0°/90°]s 與 [0°/90°/90°/90°]s）進行評估。透過拉伸剪切試驗與破壞模式觀察，分析其最大載重、剛性、能量吸收與膠層破壞後的殘餘強度等指標。 結果顯示，採用後固化膠層的混合接頭（PC-SPR 與 PHPC-SPR）在承載能力與剛性方面皆明顯優於傳統R-SPR接頭。其中，PHPC-SPR接頭因預鑽孔設計改善鉚釘展開與機械互鎖效果，於膠層失效後仍具優異的殘餘強度。此外，交錯鋪層（[0°/90°/0°/90°]s）在能量吸收與應力分散表現上明顯優於單向集中鋪層（[0°/90°/90°/90°]s），顯示纖維結構對接頭行為具有顯著影響。 本研究之創新點在於使用固定厚度的碳纖維預浸布取代傳統膠水型黏著劑作為膠合介面。此方法除可有效控制膠層厚度外，亦特別適用於具曲率或不平整表面之結構體，在實務應用中更具一致性與可操作性，提供異材接合設計與製程應用之新選擇。 ;This study investigates the mechanical performance of hybrid single-lap joints between carbon fiber reinforced polymer (CFRP) laminates and aluminum alloys, focusing on the effects of fiber stacking sequence and joint design. Four self-piercing riveting (SPR) configurations—conventional (R-SPR), post-cured with prepreg (PC-SPR), pre-holed (PH-SPR) and pre-holed post-cured with prepreg (PHPC-SPR)—were evaluated under two stacking sequences: [0°/90°/0°/90°]s and [0°/90°/90°/90°]s. Mechanical tests including tensile-shear experiments and failure mode analysis were conducted to assess joint quality, maximum load, stiffness, energy absorption, and residual strength. The results show that hybrid joints incorporating post-cured adhesive layers significantly outperformed conventional R-SPR joints in terms of load capacity and stiffness. Notably, PHPC-SPR joints exhibited superior residual strength after adhesive failure, attributed to enhanced rivet interlock through pre-drilled holes. The [0°/90°/0°/90°]s lay-up demonstrated better energy dissipation and load distribution compared to [0°/90°/90°/90°]s, confirming the critical influence of fiber architecture. A key innovation of this study lies in the use of fixed-thickness carbon fiber prepreg as the adhesive layer, rather than conventional liquid adhesives. This approach not only improves control over bonding layer thickness but also offers practical advantages for bonding curved or uneven surfaces, where uniform adhesive application is typically challenging. The prepreg method ensures better surface conformity and dimensional consistency, making it highly applicable to real-world composite structures.
