Research Progress on Fiber Reinforced Polymer/Metal Hybrid Structures for Automotive Applications

ABSTRACT Achieving the carbon peaking and carbon neutrality goals represents a critical technological imperative for the automotive industry, with lightweighting emerging as a pivotal pathway. Fiber‐reinforced polymer (FRP)/metal hybrid structures synergistically combine the low density, high specific strength/stiffness, tunable properties, exceptional design flexibility, and versatile manufacturability of FRP composites with stable strength, the ductility, cost‐effectiveness, and mature processing technologies of metallic materials. The synergistic integration enables automotive components to achieve optimized performance, weight reduction, and enhanced cost‐effectiveness. This paper systematically reviews global research advancements in FRP/metal hybrid structures for automotive. It comprehensively examines experimental methodologies for characterizing mechanical properties, constitutive modeling approaches for constituent materials, multi‐scale analysis techniques, and failure mechanisms. Special emphasis is placed on interfacial bonding, with detailed analysis of how physical, chemical, and integrated surface treatments influence interfacial bonding performance. The discussion extends to multi‐objective, multidisciplinary optimization methodologies that target the enhancement of structural strength, stiffness, and energy absorption by strategically controlling interface performance, connection processes, and design parameters. Practical automotive applications of FRP/metal hybrid structures are subsequently demonstrated. Finally, the study synthesizes current research trends and proposes future development directions, providing the foundation for advancing FRP/metal hybrid structures research and industrial implementation.