A study on the strength of adhesively bonded joints with different adherends

In this study, mechanical properties of adhesively bonded single-lap joint (SLJ) geometry with different configurations of lower and upper adherends under tensile loading were investigated experimentally and numerically. The adherends were AA2024-T3 aluminum and carbon/epoxy composite with 16 laminates while, the adhesive was a two-part liquid, structural adhesive DP 460. In experimental studies, four different types of single-lap joints were produced and used namely; composite–composite (Type-I) with lower and upper adherends of the same thicknesses and four different stacking sequences, composite–aluminum (Type-II) with lower and upper adherends of the same thicknesses and four different stacking sequences, composite–aluminum (Type-III) with lower adherend (composite) of the same thickness but upper adherend of three different thicknesses, aluminum–aluminum (Type-IV) with lower adherend of the same thickness but upper adherend of three different thicknesses, composite–composite (Type-V) with [0]₁₆ stacking sequences and three different overlap length, aluminum–aluminum (Type-VI) with three different overlap length. In the numerical analysis, the composite adherends were assumed to behave as linearly elastic materials while the adhesive layer and aluminum adherend were assumed to be nonlinear. The results obtained from experimental and numerical analyses showed that composite adherends with different fiber orientation sequence, different adherend thicknesses and overlap length affected the failure load of the joint and stress distributions in the SLJ.     

Analysis of adhesively bonded CFRE composite scarf joints modified with MWCNTs

The main objective of the present work is to improve the performance of bonded joints in carbon fiber composite structures through introducing Multi-Walled Carbon Nanotubes (MWCNTs) into Epocast 50-A1/946 epoxy, which was primarily developed for joining and repairing of composite aircraft structures. Results from tension characterizations of structural adhesive joints (SAJs) with different scarf angles (5–45°) showed improvement up to 40% compared to neat epoxy (NE)–SAJs. Special attention was considered to investigate the performance of SAJs with 5° scarf angle under different environments. The tensile strength and stiffness of both NE-SAJs and MWCNT/E-SAJs were dramatically decreased at elevated temperature. Water absorption showed a marginal drop of about 2.0% in the tensile strength of the moist SAJs compared to the dry one. Cracks initiation and propagation were detected effectively using instrumented-SAJs with eight strain gauges. The experimental results agree well with the predicted using three-dimensional finite element analysis model.     

Analysis of the stress distribution of crimped pultruded composite rods subjected to traction

The stress state of crimped pultruded composite rods subjected to traction has been investigated analytically using the linear theory of elasticity of anisotropic body and the superposition principle. The theoretical solution is able to reproduce the finite element analysis results and clarify the relation between the stress state and the boundary stresses. It can be appreciated from the theoretical solution that a longitudinal compressive stress at the edge of the crimping zone is generated by the boundary shear stress induced by the flow of metal end-fitting. Thus it can be deduced that the stress concentration at the edge of crimping zone could be mitigated through appropriately increasing the extent of the flow of the metal end-fitting away from the middle of the crimping zone. Our research shows that a radial tensile stress existing at the edge of the crimping zone is corresponding to the area of the rod that axial splitting is taken place. Comparison between analytical and numerical results shows the analytical results are in good agreement with the numerical ones except for stress distribution at the edge of the loading zone. The detailed study on stress state at the edge of the crimping zone provides better understanding of the failure mechanism, the improvement possibilities on the crimping technique and the monitoring of the structural health of the composite rod.     

Testing and modeling of Nomex™ honeycomb sandwich Panels with bolt insert

Nomex™ honeycomb core sandwich panels with a bolt insert were load tested and modeled. The objective was to predict the honeycomb local buckling load and to identify a Nomex™ honeycomb constituent material model. Sandwich specimens were subjected to bolt pull-out load tests. The same sandwich structure was also tested in flat-wise tension with strain gages installed on the honeycomb walls. Finite element models of the flat-wise tension and bolt pull-out tests were built. The honeycomb geometry and strain gages were modeled with shell elements. An orthotropic honeycomb material model was identified by comparing the two test models to the experimental data. The material parameters identified are in the mid-range of previously published values. The pull-out test model was used to predict honeycomb wall buckling with a nodal rotation vector sum criterion. The buckling loads predictions closely corresponded to the start of the experimental load/displacement slope transition zone.     

Design, testing, and FEM simulation of interlaced fiber composite structures

Design, testing, and FEM simulation of FRP structural parts manufactured using continuous fiber and light-curing resin are presented in this study. The structures can be described as formed by girders spaced by skew ribs. The study was limited to plane structures with two girders and 45° ribs between girders. Roving was positioned along the girders and the ribs so that fibers were interlaced at the joints between the ribs and girders. Several deposition paths were designed. They differ by interlacing, and proportions of fiber in the girders and ribs. Overall stiffness and strength of the structures were investigated in bending, and local deformations were measured with the strain gauges. Finite element modeling of four-point bending test for some test pieces were carried out using commercial code ANSYS to predict the deflection and the strains.     

End geometry and pin-hole effects on axially loaded adhesively bonded composite joints

An experimental investigation was performed to analyze the potential impacts of varying joint region geometries and adhesive filled pin holes on adhesively bonded composite structures. Tapers, especially half-length ones are observed to provide an anticipated progress in single lap joints. Besides, scarf joints with aligned adherends in the same plane exhibited enhanced stiffness and strength in consideration of single lap joints. In terms of the stiffness and strength, thickening of adherends was also found to be impressively efficient on composite single lap joints as well as scarf joints. Contrary to the expectation of that the hardened adhesive previously filled into the holes during adhesion would create a pin effect in load bearing, holey specimens exhibited poor performance and induced degradation in joint quality.     

Numerical evaluation for debonding failure phenomenon of adhesively bonded joints at cryogenic temperatures

In the present study, material characteristics, such as inelastic constitutive behaviour and debonding failure, of an adhesively bonded joint (ABJ) at cryogenic temperature have been evaluated using a computational approach. The modified Bodner-Partom model (BP model) has been introduced to describe the material nonlinearities of ABJ. The Gurson-Tvergaard model (GT model) has also been implemented into the constitutive model in order to analyse the phenomenon of debonding failure. An ABAQUS user-defined subroutine UMAT is developed using a damage-coupled constitutive model based on an implicit formulation. The numerical results are compared with a series of lap shear tests of ABJ at cryogenic temperature in order to verify the proposed method.     

Preparation and thermodynamic analysis of the porous ZrO2/(ZrO2 + Ni) functionally graded bolted joint

Ceramic–metal functionally graded materials (FGMs) have been extensively used in aerospace engineering where high strength and excellent heat insulation materials are desired. In this paper, the thermodynamic behavior of the Thermal Protection System (TPS) used bolted joints made up of porous ZrO₂/(ZrO₂ + Ni) FGMs is investigated by finite-element (FE) modeling. The bolted joint is subjected to reentry heating corresponding to the Access to Space Vehicle. Thermodynamic simulations are carried out to yield the transient response of the porous ZrO₂/(ZrO₂ + Ni) functionally graded bolted joint (FGBJ). The effects of the preload on the thermomechanical behavior and service reliability of the bolted joint are numerically analyzed in detail by ABAQUS codes. It is found that the preload relaxation of the bolted joint occurs at elevated temperature, and the preload has significant influence on service reliability of the bolted joint under transient thermomechanical circumstances. With the increase of the preload, stress concentration which occurs at the root of the first thread of the bolt increases rapidly and predominates in service reliability. Proper preload is thus defined to balance the service reliability and tightness of the bolted joint. Further studies show that the shape of the nut has a great effect on the stress concentration of the thread, the optimized nut is designed to reduce the stress concentration of the thread, and thus the reliability of the bolted joint is also improved.     

Numerical experimental analysis of hybrid double lap aluminum-CFRP joints

Due to their reliability and ease of assembly, both the adhesively bonded and the mechanical joints are commonly used in different fields of modern industrial design and manufacturing, to joint composite materials or composites with metals.As it is well known, adhesively bonded joints are characterized by high stiffness and good fatigue life, although delamination phenomena localized near the free edges may limit their use, especially for applications where corrosive environments and/or moisture can lead to premature failure of the bonding. In these cases, a possible alternative is given by the well-known mechanical joints. On the contrary, these last joints (bolted, riveted) require a preliminary drilling of the elements to be joined, that may cause localized material damage and stress concentration, especially for anisotropic laminates characterized by high stress concentration factors and easy drilling damaging, with significant decrease of the load-carrying capacity of the joined elements. In order to exploit the advantages of the bonded joints and those of the mechanical joints, both industrial manufacturing and research activity have been focused recently on the so called hybrid joints, obtained by the superposition of a mechanical joint to a simple adhesively bonded joint.In order to give a contribution to the knowledge of the mechanical behavior of hybrid bonded/riveted joints, in the present work a numerical–experimental study of bonded/riveted double-lap joints between aluminum and carbon fiber reinforced polymer (CFRP) laminates, has been carried out. It has permitted to highlight both the static and the fatigue performance of such joints obtained by using aluminum and steel rivets, as well as to known the particular damage mechanisms related also to the premature localized delamination of the CFRP laminate due to the riveting process.     

Progressive damage analysis as a design tool for composite bonded joints

This paper discusses the application of progressive damage analysis (PDA) methods as a design tool. Two case studies are presented in which the effects of changing design features on the strength of bonded composite joints are evaluated. It is shown that the trends of parametric evaluations performed with full-featured PDA models can be unintuitive and the trends can be opposite to those obtained with traditional design criteria. The joint configurations that were tested exhibit multiple damage modes, requiring several different PDA tools to accurately predict the structural peak loads. For damage tolerant structures that exhibit complex sequences of multiple failure mechanisms, traditional failure prediction tools are insufficient. Parametric PDA models encompassing a bonded joint specimen's design space have the potential to reveal unintuitive and advantageous design changes.     

Mechanical characterization of rubberized concrete using an image-processing/XFEM coupled procedure

A coupled (two-step) numerical procedure to characterize the mechanical behaviour of Rubberized Concrete (RuC) is proposed and validated in this paper. In particular, the splitting tensile strength test is described in detail. In the first step, MATLAB Image Processing is used to obtain the model geometry and the RuC heterogeneous configuration (distribution of rubber particles within the concrete matrix). In the second step, the Extended Finite Element Method (XFEM) included in ABAQUS software is used to simulate the inelastic behaviour of the concrete matrix and allow the nucleation and development of cracks, as well as the damage evolution and ultimate strength of the RuC specimen cross-section. Additionally, a set of experimental results on mechanical behaviour of RuC is presented. This shows that RuC has both lower strength and stiffness but higher ductility (less brittle behaviour) than normal concrete (NC). Finally, a good agreement between the two-step procedure results and the experimental results (in terms of indirect tensile strength, stiffness and failure mode) is observed.     

Contribution to the understanding of the mechanical behaviour of CFRP-strengthened RC beams subjected to fire: Experimental and numerical assessment

Recent experimental tests and numerical simulations about the fire resistance behaviour of CFRP-strengthened RC beams proved that CFRP strengthening systems are able to attain considerable fire endurance, provided that adequate fire protection systems are used. In a fire event, even though a CFRP laminate may rapidly debond from the central part of the beam in which it is installed, if sufficiently thick insulation is applied in the anchorage zones, the laminate transforms into a “cable” fixed at the extremities, thus maintaining a considerable contribution to the mechanical response of the strengthened beam. This paper presents experimental and numerical investigations on CFRP-strengthened RC beams with the objective of understanding in further depth their fire resistance behaviour, namely the influence of the above mentioned “cable” mechanism on the mechanical response of the beams. The experimental campaign, performed at ambient temperature, comprised 4-point bending tests on RC beams strengthened with CFRP laminates according to either the EBR or the NSM techniques, in both cases fully or partially (only at the anchorages, thus simulating the cable mechanism) bonded to the soffit of the beams. For the test conditions used in this study, for both types of strengthening systems, partially bonding the CFRP laminates did not affect the stiffness of the beams and caused only a slight reduction of their strength (6–15%). The numerical study comprised the simulation of the structural response of all beams tested. Non-linear finite element models were developed in Atena commercial package, in which a smeared cracked model was adopted to simulate concrete and appropriate bond-slip constitutive relations were defined for the CFRP-concrete interfaces. A very good agreement was obtained between experimental data and numerical results, providing further validation to the “cable” mechanism and the possibility of taking it into account when designing fire protection systems for CFRP-strengthened RC beams.     

An experimental and finite element study of the transverse bending behaviour of CFRP composite T-joints in vehicle structures

The behaviour of a woven fabric carbon/epoxy composite T-joint (representing a simplified version the T-joint located at the connection between the B-pillar and the longitudinal rocker in a car body structure) is investigated using experimental and numerical methods. Details of the manufacturing process and experimental design factors are considered to understand their influence on the performance of the T-joint structure. The experimental results reveal the influence of manufacturing process and experimental setup on the load-carrying capacity and failure mode of the T-joint. Numerical simulation accurately predicts the stress distribution and load-carrying capacity of the T-joint obtained from experimental tests. The FEM model, which includes the adhesive interface layers at the edges, convincingly represents the experimentally found stiffness: the error is less than 3%. According to Hashin matrix tension criteria, the first ply failure occurs at 3.746 kN when the Hashin failure index (R) becomes equal to 1. Whereas, in the case of experimental tests, the first ply failure occurs around 3.4 kN, at which force the first load drop is observed.     

Structural design of single lap joints with delaminated FRP composite adherends

This paper deals with the structural design of single lap joints (SLJs) with delaminated adherends using fracture mechanics principles. The interlaminar stresses and Strain Energy Release Rate (SERR) are considered as damage characterizing parameters used for designing the SLJ when delamination damages are pre-embedded in both the adherends at similar positions. Three dimensional geometrically non-linear finite element analyses (FEAs) of SLJ with delaminated adherends have been performed to determine the interlaminar and SERR values along the delamination fronts by simulating the simultaneous interaction delamination damages when pre-embedded at similar positions in both the adherends. SERR values are evaluated using Modified Crack Closure Technique (MCCI) which is based on energy principle. The delaminations are assumed to be of linear front, and have been considered to be embedded in both the laminated FRP composite adherends beneath the surface ply of the adhesively bonded SLJ. The delamination damages are presumed either to pre-exist or get evolved at the interlaminar locations. Such delaminations have been modelled using the sublaminate technique. The critical issues of modelling pre-embedded delamination damages are discussed in detail. The numerical results presented in this paper are based on the validated FE model compared with the available literature. Based on the present analyses, the structural design recommendations have been made for the SLJ when pre-embedded delamination damages are present in both the adherends. It is observed from the stress based design that the delamination damage when present in the bottom adherend is more detrimental for failure of SLJ compared to that for the case when it is present in the top adherend. Also, SERR based design reveals that the opening mode predominantly governs the propagation of delamination damage for all positions of the pre-embedded delaminations in both the adherends of the SLJ.     

Fabrication of reduced graphene oxide nanosheets reinforced Sn–Bi nanocomposites by electro-chemical deposition

Novel Sn–Bi/reduced graphene oxide nanosheets (RGOS) nanocomposites were fabricated using electro-chemical deposition process at room temperature. The RGOS dispersed and distributed in Sn–Bi alloy. Nano-sized Sn–Bi grain clusters grew on the surface of RGOS and the Sn–Bi grains became finer after the incorporation of RGOS. The mechanical properties including micro-hardness and shear strength were enhanced by the incorporation of RGOS. The enhance mechanism of RGOS in Sn–Bi/RGOS nanocomposites was proposed by finite element method simulation. The graphene with extra-thin thickness and huge aspect ratio lead to an effective stress transfer and stress concentration occurs near the edge of graphene. The Sn–Bi/RGOS nanocomposites are promising in application as TIM of high power electronics, integrated circuits.     

An experimental–numerical investigation of hydrothermal response in adhesively bonded composite structures

Water absorption and thermal response of adhesive composite joints were investigated by measurements and numerical simulations. Water diffusivity, saturation, swelling, and thermal expansion of the constituent materials and the joint were obtained from gravimetric experiments and strain measurements using embedded fiber Bragg grating (FBG) sensors. The mechanical response of these materials at different temperatures and water content was characterized by dynamic mechanical analysis. Thermal loading and water absorption in joint specimens were detected by monitoring the FBG wavelength shift caused by thermal expansion or water swelling. The measured parameters were used in finite element models to simulate the response of the embedded sensor. The good correlation of experimental data and simulations confirmed that the change in FBG wavelength could be accurately related to the thermal load or water absorption process. The suitability of the embedded FBG sensors for monitoring of water uptake in adhesive composite joints was demonstrated.     

Numerical study of the structural behaviour of impacted composite laminates subjected to compression load

Composite materials allow all the benefits which a high specific strength involves, in a design process their application involves many critical problems. Currently, these problems, such as environmental conditions, notch sensitivity, damaging under low velocity impacts, are taken into account by means of the application of conservative design safety factors regarding the ultimate tensile strength. In order to try to reduce these safety factors, this work aimed to study and to understand the impact damage growing mechanisms due to compression loads. To this purpose, compression tests have been experimentally performed on composite panels, which have been previously subjected to low velocity impact phenomena, considering impact energies of 6 J, 10 J and 13 J respectively. Moreover, numerical model able to simulate Low Velocity Impacts (LVI) and Compression After Impacts (CAI) onto CFRP panels is proposed. A single explicit finite element analysis has been carried out by using the Abaqus^® finite element code; the need to build a numerical model, which allows simulation in only one analysis both LVI and CAI steps, depends on the difficulty to import the impact damage distribution into a separate compression analysis. In fact, in only one analysis the compression step can occur directly onto the impacted plate, which allows to consider the effective impact damage distribution as the starting configuration for quasi static analysis under operating loads.     

Failure analysis of adhesively bonded composite joints under transverse impact and different temperatures

In this study, load-carrying capacity of a single-lap joint bonded by an adhesive was found by experimental method. Glass fiber–epoxy composites were used as adherends. They were manufactured by using vacuum assisted resin infusion method (VARIM). Loctite 9466 A&B2 was used as an adhesive material. In this experimental study, two different surfaces (rough and smooth surface), four different temperatures (−20, 23, 50, and 80 °C) and four different impact energies (5, 10, 15, and 20 J) were considered. The result shows that when the temperature increases or decreases, adhesive joint losses its adhesion and rough surfaces provide high strength according to smooth surfaces. Load-carrying capacity decrease at 5, 10 and 15 J; however, it increases for 20 J.     

Press forming a 0/90 cross-ply advanced thermoplastic composite using the double-dome benchmark geometry

A pre-consolidated thermoplastic advanced composite cross-ply sheet comprised of two uniaxial plies orientated at 0/90° has been thermoformed using tooling based on the double-dome bench-mark geometry. Mitigation of wrinkling was achieved using springs to apply tension to the forming sheet rather than using a friction-based blank-holder. The shear angle across the surface of the formed geometry has been measured and compared with data collected previously from experiments on woven engineering fabrics. The shear behaviour of the material has been characterised as a function of rate and temperature using the picture frame shear test technique. Multi-scale modelling predictions of the material’s shear behaviour have been incorporated in finite element forming predictions; the latter are compared against the experimental results.     

Determination of cohesive laws of composite bonded joints under mode II loading

In this work, mode II cohesive laws of carbon–epoxy composite bonded joints were obtained using the direct method applied to the end notched flexure (ENF) test. The direct method is based on the differentiation of the relation between the evolution of the fracture energy (J_II) and the crack tip opening displacement in mode II (CTOD_II) during the test. A data reduction scheme based on equivalent crack length concept was used to obtain the evolution of the fracture energy during the test. The method allows overcoming problems related to identification of crack tip in mode II tests and the presence of a non-negligible fracture process zone (FPZ), which both difficult the right estimate of J_II. The digital image correlation technique (DIC) was used to monitor the CTOD_II, which was synchronized with the load–displacement data. A trapezoidal cohesive law was fitted to the experimental one in order to perform numerical simulations using finite element analysis. The main goal was to validate all the procedure used to get the cohesive laws. The good agreement obtained between the numerical and experimental load-CTOD_II curves and between the cohesive laws demonstrates the adequacy of the proposed procedure concerning the evaluation of the composite bonded joints cohesive laws under mode II loading.