{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2025,12,26]],"date-time":"2025-12-26T05:21:07Z","timestamp":1766726467070,"version":"3.48.0"},"reference-count":51,"publisher":"MDPI AG","issue":"1","license":[{"start":{"date-parts":[[2025,12,24]],"date-time":"2025-12-24T00:00:00Z","timestamp":1766534400000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Metals"],"abstract":"<jats:p>In this research, we assess the feasibility of employing hybrid friction stir channeling (HFSC) to produce composite panels that combined an 8 mm thick AA6082-T6 aluminum alloy and 5 mm thick glass-fiber-reinforced Noryl GFN2. HFSC is an innovative solid-state technology that combines both friction stir joining and channeling characteristics, which enable the generation of integral internal channels while joining different components. A parametric study was outlined to explore the effects of the travel speed, probe length, and tool plunging on the resulting composite panels. The resulting composite panels were subsequently subjected to a comprehensive analysis encompassing exterior ceiling quality, internal channel, and joining interface morphology. Depending on the processing parameters, the geometry of the channels was found to be quasi-rectangular or quasi-trapezoidal, with significant variability on cross-sectional area, resulting in hydraulic diameters ranging from 1.2 to 2.9 mm. The joining interface was characterized by a concavity of aluminum that was extruded downwards into the polymeric molten pool, which was clinched after polymeric re-solidification. The experimental results prove the ability to join metals and polymers while creating an integral channel in a single process step using HFSC. Despite the positive effect of irregular shaped channels on heat exchange, the numerical models evidenced a detrimental effect of 14.3 and 16.3% on ultimate tensile and flexural loads, respectively. This way, this fabrication technology evidenced promising characteristics that are suitable for manufacturing thermal management systems such as conformal cooling for plastic injection molding or battery trays for EVs.<\/jats:p>","DOI":"10.3390\/met16010016","type":"journal-article","created":{"date-parts":[[2025,12,24]],"date-time":"2025-12-24T11:22:14Z","timestamp":1766575334000},"page":"16","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":0,"title":["Innovative Metal\u2013Polymer Composite Panels with Integrated Channels for Thermal Management Systems Using Hybrid Friction Stir Channeling\u2014HFSC"],"prefix":"10.3390","volume":"16","author":[{"ORCID":"https:\/\/orcid.org\/0000-0001-8165-5946","authenticated-orcid":false,"given":"Arm\u00e9nio N.","family":"Correia","sequence":"first","affiliation":[{"name":"Instituto Superior T\u00e9cnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisboa, Portugal"}]},{"given":"Virg\u00ednia","family":"Infante","sequence":"additional","affiliation":[{"name":"LAETA, IDMEC, Instituto Superior T\u00e9cnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisboa, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-0587-3041","authenticated-orcid":false,"given":"Daniel F. O.","family":"Braga","sequence":"additional","affiliation":[{"name":"INEGI, Faculdade de Engenharia, Universidade do Porto, Rua Dr. Roberto Frias, 400, 4200-465 Porto, Portugal"}]},{"given":"Ricardo","family":"Baptista","sequence":"additional","affiliation":[{"name":"UnIRE, ISEL\u2014Instituto Superior de Engenharia de Lisboa, Instituto Polit\u00e9cnico de Lisboa, Rua Conselheiro Em\u00eddio Navarro, 1959-007 Lisboa, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-4749-3036","authenticated-orcid":false,"given":"Pedro","family":"Vila\u00e7a","sequence":"additional","affiliation":[{"name":"Department of Energy and Mechanical Engineering, School of Engineering, Aalto University, 02150 Espoo, Finland"}]}],"member":"1968","published-online":{"date-parts":[[2025,12,24]]},"reference":[{"key":"ref_1","unstructured":"European Environment Agency (2022). 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