An essential consideration for metal-polymer applications is that the sound joining of these materials is challenging due to a significant surface energy differential in different structural characteristics between polymer and metal. However, the joining methods have some drawbacks, such as low-reliability joints, long curing time, stress concentration, and polymer degradation. A new novel metal-polymer hybrid joining technique is proposed in this work to overcome these issues and cost perspectives, manufacturing, and overcoming the problem of PVC degradation due to heat generation of other joining methods. In this study, we managed to join PVC to AA5053 sheets using a cold joining technique based on extruding PVC through a conical hole of an aluminum specimen using a punching tool. Experiments consisted of three parameters (the hole diameter, plunging depth, and radius of the punch), with four levels for each parameter. The experiments were designed, and mechanical characterizations of the joints were optimized using the design of the experiment's method. The hole diameter was the effective parameter on the mechanical characterizations and dimensions of the extruded PVC. Increasing the diameter of the AA5053 sheet increased the maximum diameter of the extruded PVC, shear force, and pull-out force of the joints and decreased the shear stress of the joints. We obtained a maximum shear strength of 106.15 MPa, which is ~3 times higher than the tensile strength of PVC (37 MPa).

金属-聚合物应用的一个重要考虑因素是，由于聚合物和金属之间的不同结构特性存在显着的表面能差异，因此这些材料的良好连接具有挑战性。然而，这些连接方法存在一些缺点，例如接头可靠性低、固化时间长、应力集中和聚合物降解。这项工作提出了一种新型金属-聚合物混合连接技术，以克服这些问题和成本观点、制造，并克服其他连接方法因发热而导致 PVC 降解的问题。在这项研究中，我们成功地使用冷连接技术将 PVC 连接到 AA5053 板材，该技术基于使用冲压工具将 PVC 挤出铝样本的锥形孔。实验包括三个参数（孔径、切入深度和冲头半径），每个参数有四个级别。设计了实验，并使用实验方法的设计优化了接头的机械特性。孔径是影响挤出PVC力学性能和尺寸的有效参数。增加AA5053片材的直径会增加挤出PVC的最大直径、接头的剪切力和拉拔力，并降低接头的剪切应力。我们获得的最大剪切强度为 106.15 MPa，比 PVC 的拉伸强度 (37 MPa) 高约 3 倍。