AbstractWith core advantages such as light weight, high strength, corrosion resistance and strong designability, com...
Abstract
With core advantages such as light weight, high strength, corrosion resistance and strong designability, composite materials have been widely used in many key sectors of the national economy, including aerospace, rail transit, automotive manufacturing, new energy, and construction engineering. In practical engineering applications, composite materials are rarely used alone; they are mostly joined, assembled or hybridized with dissimilar materials such as metals, ceramics and polymers. The compatibility between these materials directly determines the structural integrity, mechanical performance stability and service life of components, and is also one of the core bottlenecks restricting the large‑scale application of composite materials.
Based on data released by authoritative institutions including the Ministry of Industry and Information Technology, the Standardization Administration of China, the National Bureau of Statistics, and the Aviation Industry Corporation of China, this paper systematically reviews the compatibility performance of composite materials with various mainstream materials (metals, ceramics and polymers). It analyzes the key influencing factors, evaluation criteria and testing methods for compatibility, discusses the current status and technical bottlenecks of research and application of composite material compatibility in China, and prospects future development trends. This study provides a reference for industrial technological innovation, engineering application optimization and relevant policy‑making, supporting the high‑quality development of the composite materials industry.
Keywords
composite materials; dissimilar materials; compatibility; mechanical properties; evaluation criteria; engineering applications
1 Introduction
As the new materials industry has become a national strategic emerging industry, the composite materials industry has entered a period of rapid development, with increasingly diversified product types and expanding application scenarios. Composite materials are composed of two or more materials with different properties through physical or chemical methods to form a new‑performance material at the macro‑ or micro‑level. According to matrix type, they are divided into three categories: polymer matrix composites, metal matrix composites, and ceramic matrix composites. Among them, polymer matrix composites account for more than 80% of the global composite market due to simple preparation and controllable cost.
In engineering applications, restricted by structural functions, manufacturing costs and processing technologies, composite materials must be used cooperatively with dissimilar materials such as metals (steel, aluminum, titanium alloys), ceramics and conventional polymers. Typical examples include joining components of carbon fiber composites and titanium alloys in aerospace, body structures of glass fiber composites and steel in automobiles, assemblies of composites and ceramic insulators in new energy systems, and composite structures of composites and concrete in construction.
The compatibility between composite materials and other materials refers to the ability of two or more materials to maintain their original properties, avoid harmful interactions, form stable bonding, and meet engineering requirements during combination, joining or service. It mainly includes four dimensions: mechanical compatibility, chemical compatibility, thermal compatibility and interfacial compatibility.
Poor compatibility leads to interfacial debonding, degradation of mechanical properties, accelerated corrosion, thermal stress cracking and other failures, seriously threatening safety and service life, even causing engineering accidents. For instance, excessive mismatch in thermal expansion coefficients between composites and metals in aero‑engines induces thermal stress and interfacial peeling, creating severe flight safety hazards. Insufficient chemical compatibility between composite battery housings and metal electrodes causes electrode corrosion and performance decay, shortening battery life.
According to the Ministry of Industry and Information Technology, China’s composite material output reached 11.5 million tons in 2025, a year‑on‑year increase of 9.2%, with a market scale exceeding 480 billion yuan. The compound annual growth rate from 2021 to 2025 reached 10.5%, among which high‑end fields such as aerospace, new energy vehicles and rail transit accounted for 42% of demand.
As high‑end equipment evolves toward lightweight, high‑performance and long‑life designs, requirements for compatibility between composites and other materials have become increasingly stringent, making compatibility research a core topic for industrial upgrading and engineering expansion. Based on official data, standards and research results, this paper systematically reviews compatibility between composites and various mainstream materials, summarizes current progress and challenges, and forecasts development trends.
2 Compatibility Performance and Influencing Factors Between Composites and Various Materials
The compatibility of composite materials is closely related to their composition (matrix, reinforcement type and content), properties of mating materials, joining/combination processes and service environment. This section focuses on the most widely used polymer matrix, metal matrix and ceramic matrix composites, and their compatibility with metals, ceramics and polymers.
2.1 Compatibility Between Composite Materials and Metallic Materials
Metals (steel, aluminum, titanium alloys, copper alloys) feature high strength, toughness, electrical and thermal conductivity, and are the most commonly paired materials with composites. According to the Aviation Industry Corporation of China, about 68% of composite structural parts in the C919 large passenger aircraft are joined with titanium or aluminum alloys, whose compatibility directly determines safety and service life.
Three major problems exist: weak interfacial bonding, electrochemical corrosion, and thermal stress mismatch.
2.1.1 Compatibility of Different Composites with Metals
Polymer matrix composites & metalsPoor compatibility, mainly due to interfacial weakness and electrochemical corrosion. The insulating resin matrix and conductive metal form a galvanic cell, causing corrosion. Interfacial bonding relies mainly on physical adsorption with low strength.
According to GB/T 3354‑2014 and GB/T 15117‑2017, the interfacial shear strength between carbon fiber reinforced epoxy and aluminum alloy is only 25–35 MPa, far below that of aluminum alloy (100–120 MPa). After 6 months in humid environments, interfacial strength decreases by more than 30%.
Metal matrix composites & metalsRelatively good compatibility owing to similar thermal expansion and mechanical properties. Interfacial shear strength between aluminum matrix composites and 6061 aluminum alloy reaches 80–100 MPa, with performance degradation below 10%. However, galvanic corrosion still occurs between dissimilar metals.
Ceramic matrix composites & metalsThe worst compatibility, dominated by severe thermal stress mismatch and interfacial reaction. The thermal expansion coefficient of ceramic matrix composites is much lower than that of metals. At high temperatures, interfacial reactions form brittle phases.
After exposure at 800 °C for 100 hours, the interfacial reaction layer between ceramic matrix composites and stainless steel reaches 5–8 μm, and shear strength drops by more than 50%.
2.1.2 Key Influencing Factors
Electrochemical potential difference: the main cause of galvanic corrosion.
Thermal expansion coefficient mismatch: the main source of thermal stress and interfacial cracking.
Interfacial bonding state: determined by surface treatment and joining processes.
According to the Composite Materials Industry Development White Paper (2025), corrosion accelerates significantly when the potential difference exceeds 0.2 V and becomes severe above 0.5 V.
2.2 Compatibility Between Composite Materials and Ceramics