A research team from the Oak Ridge National Laboratory (ORNL) has developed a laser process that could make joining carbon fiber composites and aluminum less expensive with more robust joints as a result. The process promises cheaper lightweight, high-end components for use in automotive manufacture.

The joining of carbon fiber composites and aluminum requires that the joined surfaces be clear of things that interfere with the bonding agents. Aluminum surfaces typically have oils and contamination from production rolling, while carbon fiber often has mold releases from the manufacturing process. 

The current practice for joining these two materials involves hand-preparing surfaces with abrasive pads and solvents. This is both labor-intensive and harmful to the environment. The ORNL team has designed a process in which lasers remove the layers of material from surfaces instead.