胶膜连接碳纤维增强树脂复合材料板-钢搭接接头室温条件的力学性能试验

针对碳纤维增强树脂（CFRP）复合材料板-钢搭接接头连接的糊状胶黏剂粘层厚一致性控制较难、铅垂向成形可能不易等问题,将糊状胶黏剂换成胶膜,制作了胶膜连接的五种粘结长度共15个CFRP板-钢双搭接接头试件,并对该胶膜连接的CFRP板-钢搭接接头进行了室温条件下的破环模式、有效粘结长度、传力规律、粘结-滑移本构、承载力等的试验研究。结果表明:所用胶膜的连接强度略高于CFRP板层间强度（即碳纤维与树脂基体的黏聚强度）;室温下,所用胶膜连接的CFRP板-钢搭接接头有效粘结长度约为80 mm;加载初期,剪应力最大值位于接头钢板端;继续加载,其位置向接头CFRP板端移动;加载末期,其位置位于距接头钢板端20 mm （粘结长度不超过80 mm时）或者50 mm （粘结长度不小于120 mm时）处;胶膜连接的CFRP板-钢搭接接头界面粘结-滑移模型为近似梯形,不同于胶黏剂连接的CFRP板-钢搭接接头的近似三角形,胶膜连接接头的延性大为提升;所用胶膜连接接头界面峰值剪应力、断裂能、界面刚度等代表值（可视为准平均值）分别为四种典型商品胶黏剂连接接头的1.2~3.0倍、1.6~5.7倍和5.4~7.5倍;在粘结长度不小于有效粘结长度条件下,所用胶膜连接接头的抗拉承载力代表值为四种典型商品胶黏剂连接接头的1.25~2.39倍;胶膜连接接头的抗拉承载力、最大位移的变异系数与糊状胶黏剂连接接头相差不大。      

On the interfacial constitutive laws of mixed mode fracture with various adhesive thicknesses

Interfacial toughness and interfacial strength, as two critical parameters in an interfacial traction–separation law, have important effect on the fracture behaviors of adhesively bonded joints. In this work, the global and local fracture tests are employed to investigate the effect of adhesive thickness on interfacial energy release rate, interfacial strength, and shapes of the interfacial traction–separation laws under the mixed I/II mode loading condition. Basically, the measured interface laws based on the single leg bending (SLB) specimens reflect the equivalent and lumped interfacial fracture behaviors which include the cohesive fracture, damage and plasticity. Several new and interesting experimental results were obtained. The experimentally determined interfacial traction–separation laws may provide valuable baseline data for the parameter calibrations in numerical models. The current experimental results may also facilitate the understanding of adhesive thickness-dependent interface fracture of bonded SLB joints.     

Shear induced toughening in bonded joints: experiments and analysis

Bonded joint specimens were fabricated from composite adherends and either an epoxy or a urethane adhesive. In mixed-mode fracture experiments, the epoxy bonded specimens generally failed by subinterfacial fracture in the composite, while specimens bonded with urethane failed very close to the adhesive/substrate interface. For the epoxy bonded specimens, fracture toughness did not change significantly with mode-mix, but for urethane bonded joints, fracture toughness increased with increasing shear load. Finite element analysis, which modeled specimens bonded with the two adhesives, showed similar trends. The different toughening behaviors for the two bonded joints can be attributed to dissipation of energy through inelastic deformation, which was insignificant in the epoxy-bonded joints but substantial when the urethane was used as the bonding agent.     

Bond–slip models for double strap joints strengthened by CFRP

This paper presents the results of a series of tension tests on CFRP bonded steel plate double strap joints. The main aim of this research is to provide detailed understanding of bond characteristics using experimental and numerical analysis of strengthened double strap joints under tension. A parametric study has been performed by numerical modelling with the variables of CFRP bond lengths, adhesive maximum strain and adhesive layer thicknesses. Finally, bond–slip models are proposed for three different types of adhesives within the range of the parametric study.     

Hybrid epoxy-silyl modified polymer adhesives for CFRP sheets bonded to a steel substrate

This paper presents an experimental study examining the interfacial behavior between a steel substrate and carbon fiber reinforced polymer (CFRP) sheets bonded with hybrid epoxy-silyl modified polymer (SMP) adhesives. The epoxy adhesive has high modulus and strength characteristics, while the SMP adhesive possesses a low modulus with permanent elastic nature. The hypothesis tested is that a combination of these two distinct materials can alleviate interfacial stresses along the bond line with maintaining adequate strength. Two types of double-lap tension tests are conducted to evaluate the bond-capacity of the epoxy and SMP adhesives and to study the effect of various hybrid bond schemes. Test results show that the specimens bonded with homogeneous epoxy demonstrate abrupt failure, whereas those with SMP exhibit gradual load-softening at failure. The load-carrying capacity and stiffness of the CFRP–steel interface are not influenced by hybrid bond configurations. The degree of CFRP-debonding is, however, affected by the hybrid bond scheme. Stress transfer from the steel substrate to the CFRP is well maintained along the hybrid bond line with significant local deformability of the interface layer. Analytical models report that shear stresses along the CFRP–steel interface are noticeably mitigated at geometric discontinuities and the proposed hybrid bond technique can be used for structure-level application.     

Failure analysis of adhesively bonded joints in composite materials

The present paper is concerned with a phenomenological model to perform the failure analysis of composite adhesive single lap joints with arbitrary glued area. The theory is conceived for joints composed by highly resistant elastic adherends bonded with brittle–elastic adhesives. It is shown that, under certain conditions, the rupture forces (in the case of monotonic loading) and lifetimes (in the case of cyclic loading) of two joints with different glued areas can be correlated using a shape factor. Results from experimental static and fatigue testing of joints with carbon/epoxy laminates bonded with epoxy adhesive and different bonding areas are compared with model prediction showing a good agreement.     

Fracture and yield behavior of adhesively bonded joints under triaxial stress conditions

Most of adhesively bonded joints are under complicatedly distributed triaxial stress in the adhesive layer. For the estimating of the strength of adhesively bonded joints, it is crucial to clarify behavior of yield and failure of the adhesives layer under triaxial stress conditions. Two types of the adhesively bonded joints were used in this study: One is the scarf joint which is under considerably uniform normal and shear stresses in the adhesive layer, where their combination ratio can be varied with scarf angle. The other is the butt joint with thin wall tube in which considerably uniform pure shear can be realized in the adhesive layer under torsional load conditions. These joints can cover the stress triaxiality in adhesive layers of most joints in industrial application. The effect of stress triaxiality on the yield and fracture stresses in the adhesive layer were investigated using the joints bonded by three kinds of adhesives in heterogeneous and homogeneous systems. The results showed that both the yield and failure criterion depend on the stress triaxiality and that the fracture mechanism of the homogeneous adhesive is different from that of the heterogeneous one. From these experimental results, a method of estimating the yield and failure stresses was proposed in terms of a stress triaxiality parameter.     

纳米SiO2质量分数对胶粘碳纤维增强树脂复合材料板-钢搭接界面黏结性能的影响

胶黏剂力学性能对碳纤维增强树脂复合材料(CFRP)加固钢结构的界面黏结性能影响显著。基于研制的胶黏剂配比,分析了不同纳米SiO₂质量分数对胶黏剂常温固化后基本力学性能及微观结构的影响,制作了31个CFRP板-钢板双搭接试件,对其进行了常温固化后的承载能力、有效黏结长度、传力模式、黏结-滑移本构等试验研究,得出了纳米SiO₂质量分数对CFRP板-钢板搭接试件界面黏结性能的影响规律,并与常用商品胶黏剂进行了比较。研究结果表明:随纳米SiO₂质量分数的增加,胶黏剂应力-应变关系由线性转变为非线性,应变能、断裂伸长率及剪切强度分别最高提升了292.10%、202.88%和133.12%。微观结构分析表明纳米SiO₂的添加使断面粗糙度显著增加,形成了密集的塑性空穴,产生了更多的微裂纹,使胶黏剂的韧性大幅度提高。当纳米SiO₂质量分数从0增至1wt%,搭接试件破坏模式由界面破坏逐渐变为CFRP板层离破坏。掺入纳米SiO₂能显著增加搭接试件的极限承载力(提升256.96%)及界面有效黏结长度(提升3倍),提高CFRP表面的应变及界面剪应力峰值。纳米SiO₂质量分数为0与0.5wt%的搭接试件的黏结-滑移曲线为双线性三角形模型,纳米SiO₂质量分数为1wt%的搭接试件的黏结-滑移曲线为三线性梯形模型,黏结界面韧性大幅提升。CFRP-钢界面承载能力受胶黏剂拉伸强度与断裂伸长率的双重影响,非线性高强度(即具有较高应变能)胶黏剂对应的CFRP-钢搭接接头具有更好的界面性能。      

Mode-I,mode-II and mixed-mode I+II fracture behavior of composite bonded joints: Experimental characterization and numerical simulation

The fracture behavior of composite bonded joints subjected to mode-I, mode-II and mixed-mode I + II loading conditions was characterized by mechanical testing and numerical simulation. The composite adherents were bonded using two different epoxy adhesives; namely, the EA 9695 film adhesive and the mixed EA 9395-EA 9396 paste adhesive. The fracture toughness of the joints was evaluated in terms of the critical energy release rate. Mode-I tests were conducted using the double-cantilever beam specimen, mode-II tests using the end-notch flexure specimen and mixed-mode tests (three mixity ratios) using a combination of the two aforementioned specimens. The fracture behavior of the bonded joints was also simulated using the cohesive zone modeling method aiming to evaluate the method and point out its strengths and weaknesses. The simulations were performed using the explicit FE code LS-DYNA. The experimental results show a considerable scatter which is common for fracture toughness tests. The joints attained with the film adhesive have much larger fracture toughness (by 30–60%) than the joints with the paste adhesive, which exhibited a rather brittle behavior. The simulation results revealed that the cohesive zone modeling method performs well for mode-I load-cases while for mode-II and mixed-mode load-cases, modifications of the input parameters and the traction-separation law are needed in order for the method to effectively simulate the fracture behavior of the joints.     

Fracture toughness of bulk adhesives in mode I and mode III and curing effect

Failure load predictions of adhesively bonded lap joints are either done based on a stress/strain limit criterion or using concepts of fracture mechanics. For the former case, the stress-strain curves of the adhesive must be determined accurately and for the latter case the toughness of the adhesive is needed. The present study gives for two adhesives, one brittle and one ductile, the strength and fracture properties in the bulk form. Stress-strain curves are given in tension and shear. The toughness was measured in mode I using a three point bending specimen and in mode III with a circular specimen with a notch under torsion. Mixed-mode criteria are discussed and it is shown that the experimental results are in good agreement with the strain energy theory. Finally, the effect of shrinkage stresses on the fracture toughness was studied and it is shown that they have a substantial effect on the fracture toughness.     

Cohesive zone modelling of interface fracture near flaws in adhesive joints

A cohesive zone model is suggested for modelling of interface fracture near flaws in adhesive joints. A shear-loaded adhesive joint bonded with a planar circular bond region is modelled using both the cohesive zone model and a fracture mechanical model. Results from the models show good agreement of crack propagation on the location and shape of the crack front and on the initial joint strength. Subsequently, the cohesive zone model is used to model interface fracture through a planar adhesive layer containing a periodic array of elliptical flaws. The effects of flaw shape are investigated, as well as the significance of fracture process parameters. The results from simulations of fracture in a bond containing circular flaws show that localization of crack propagation in the vicinity of a flaw has significant effect on the joint strength and crack front shape. The localization effects are highly dependent on the fracture process zone width relative to the flaw dimensions. It is also seen that with increasing fracture process zone width, the strength variation with the flaw shape decreases, however, the strength is effected over a wider range of propagation.     

Composite-to-metal tubular lap joints: strength and fatigue resistance

The axial strength and fatigue resistance of thick-walled, adhesively bonded E-glass composite-to-aluminum tubular lap joints have been measured for tensile and compressive loadings. The joint specimen bonds a 63 mm OD aluminium tube within each end of a 300 mm long, 6 mm thick E-glass/epoxy tube. Untapered, 12.5 mm thick aluminium adherends were used in all but four of the joint specimens. The aluminum adherends in the remaining four specimens were tapered to a thickness of 1 mm at the inner bond end (the bond end where the aluminum adherend terminates). For all loadings, joint failure initiates at the inner bond end as a crack grows in the adhesive adjacent to the interface. Test results for a tension-tension fatigue loading indicate that fatigue can severely degrade joint performance. Interestingly, measured tensile strength and fatigue resistance for joints with untapered adherends is substantially greater than compressive strength and fatigue resistance.The joint specimen has been analyzed in two different ways: one approach models the adhesive as an uncracked, elastic-perfectly plastic material, while the other approach uses a linear elastic fracture mechanics methodology. Results for the uncracked, elastic-plastic adhesive model indicate that observed bond failure occurs in the region of highest calculated stresses, extensive bond yielding occurs at load levels well below that required to fail the joint, and a tensile peel stress is generated by a compressive joint loading when the aluminum adherends are untapered. This latter result is consistent with the observed joint tensile-compressive strength differential. Results of the linear elastic fracture mechanics analysis of a joint with untapered aluminum adherends are also consistent with the observed differential strength effect since a mode I crack loading is predicted for a compressive joint loading. Calculations and a limited number of tests suggest that it may be possible to selectively control the differential strength effect by tapering the aluminum adherends. The effect of adherend material and thickness on fracture mechanics parameters is also investigated. The paper concludes by examining the applicability of linear elastic fracture mechanics to the joints tested.     

Fracturing behaviors of FRP-strengthened concrete structures

In this paper, we focus on the study of concrete cracking behavior and interfacial debonding fracture in fiber reinforced polymer (FRP)-strengthened concrete beams. An experimental program is systematically reviewed according to the observed failure modes, in which it is found that the interfacial debonding may propagate either within the adhesive layer or through concrete layer in the vicinity of bond interface. A finite element analysis is performed to investigate the different types of debonding propagation along FRP-concrete interface and crack distribution in concrete. For the numerical fracture models, interfacial debonding that initiates and propagates in adhesive layer is modeled by fictitious interfacial crack model. And concrete cracking, including the debonding fracture through interfacial concrete, is modeled by smeared crack model. Properties of the interfacial adhesive layer and concrete are considered to significantly influence the debonding propagation types and crack distribution. The interactions between interfacial bond strength, interfacial fracture energy of bond adhesive layer and tensile strength, fracture energy of concrete are discussed in detail through a parametric study. According to the results, the effects of these properties on different types of interfacial debonding, concrete cracking behavior and structural load-carrying capacity are clearly understood.     

Interfacial debonding of pipe joints under torsion loads: a model for arbitrary nonlinear cohesive laws

Adhesively bonded pipe joints are extensively used in pipelines. In the present work, Cohesive Zone Model (CZM) based analytical solutions are obtained for the bonded pipe joints under torsion. An integral form based general expression is derived which is suitable for arbitrary type of nonlinear cohesive laws. The concept of the minimum interfacial cohesive shear slip δ _m is introduced and used in the fundamental expression of the external torsion load. It is found that, when the bond length of the pipe joint is large enough, the torsion load capacity is indeed independent of the shape of cohesive laws and the bond length. It is interesting to note that the maximum torsion load capacity is achieved when the torsion stiffness of the pipe and coupler are identical. A good agreement with finite element analysis (FEA) result indicates that the current model works well. The formulation to develop a simple test method for determining the τ–δ constitutive relationship in pipe joints under torsional loads is suggested. Parametric studies of various cohesive laws are conducted. This model deepens the understanding of the interfacial debonding problem of bonded joints. The fracture energy based formulas of the torsion load capacity derived in the present work can be directly used in the design of adhesively bonded pipe joints.     

Mode II fracture energy characterization of brittle adhesives using compliance calibration method

The end‐notched flexure (ENF) test is widely used for measuring the Mode II critical strain energy release rate of adhesively bonded joints (ABJs). Unstable crack growth in ENF joints with brittle adhesives is a common phenomenon. Classic data reduction methods like the direct beam theory (DBT) and the compliance‐based beam method (CBBM) usually result in unacceptable scatter when crack grows unstable. In this study, the application of a compliance calibration method (CCM) for ENF adhesive joints with a brittle adhesive is experimentally investigated. For this purpose, ENF specimens were manufactured and tested. Different data reduction methods were considered for treating the results. Afterwards, the obtained fracture energies were used as an input parameter in a finite element (FE) analysis with a cohesive zone model to evaluate the validity of the experimental data. It is shown that the fracture loads obtained by the CCM have the best agreement with the experimental ones comparing with the other data reduction approaches. To study the effect of geometry on the CCM results, ENF specimens with different adhesive thicknesses, substrate thicknesses and span lengths were also considered in this study, and some general conclusions are made about the geometrical parameters effect on the Mode II fracture energy.     

Cohesive failure of adhesive joints

Abstract

Present interest in adhesives is intense, since in many ways they provide the ideal means of joining components, especially those assembled by robot techniques. In this paper, it is shown how the measured strength of an adhesive joint reflects the interaction between the properties of substrate, adhesive, and the interface between them. Work is discussed which shows how the peel strengths of model systems have been varied by both altering the interfacial bonding and changing the mechanical properties of the adhesive. Appropriate changes to surface topography as well as the introduction into the adhesive of second ‘phases’, which may be hard or soft, or even bubbles, can produce significant joint toughening in a range of adhesive joints. For the future, improved prediction of joint service properties from design data is to be expected. This will come from the further application to adhesive joints of fracture mechanics, time–temperature superposition techniques, slipline field theory, and finite element analysis.

MST/723     

The determination of the mode II adhesive fracture resistance, GIIC, of structural adhesive joints: an effective crack length approach

This paper reports results from the mode II testing of adhesively-bonded carbon-fibre-reinforced composite substrates using the end-loaded split (ELS) method. Two toughened, structural epoxy adhesives were employed (a general purpose grade epoxy-paste adhesive, and an aerospace grade epoxy-film adhesive). Linear Elastic Fracture Mechanics was employed to determine values of the mode II adhesive fracture energy, G_IIC for the joints via various forms of corrected beam theory. The concept of an effective crack length is invoked and this is then used to calculate values of G_IIC. The corrected beam theory analyses worked consistently for the joints bonded with the epoxy-paste adhesive, but discrepancies were encountered when analysing the results of joints bonded with the epoxy-film adhesive. During these experiments, a microcracked region ahead of the main crack was observed, which led to difficulties in defining the true crack length. The effective crack length approach provides an insight into the likely errors encountered when attempting to measure mode II crack growth experimentally.     

Structural behavior and inter-layer displacements in CFRP plated steel beams – Optical measurements,analysis, and comparative verification

The linear elastic structural behavior of steel beams strengthened with externally bonded composite materials is experimentally and analytically investigated. The paper focuses on the full-field inter-layer relative displacements between the beam and the FRP layer. Such displacements result from the interaction between the adhesively bonded components and it is the integrated outcome of the interfacial conditions and the deformability of the adhesive. As such, it is commonly adopted as the state variable in simplified bond shear stress–slip representations. This aspect, as well as other aspects of the global and localized structural response, is analytically and experimentally quantified. The experiment includes a simply supported steel beam strengthened with a CFRP plate. A 3D image correlation technique with sequential measurements is used for the assessment of the full-field inter-layer displacements along the beam. The analysis adopts a high order modeling approach that accounts for the 2D stress and displacement fields through the depth of the adhesive and a 1D shear stress–slip approach using only a linear increasing branch. The comparison between the results provides validation of the analytical and experimental capabilities with emphasis on the inter-layer effects. One of the interesting findings which is discussed and explained in this paper is the fact that the slip values calculated with the shear stress–slip approach are notably different from the ones that can be measured experimentally and determined by the high order model.     

Effects of bondline thickness on Mode-I nonlinear interfacial fracture of laminated composites: An experimental study

Delamination or interfacial fracture is one of the most important issues for laminated composite structures. For the recent two decades, cohesive zone models (CZMs) have been receiving intensive attentions for modeling interfacial fracture of composite structures. Numerous global fracture tests have been conducted to measure the interfacial toughness of laminated composite plates. Some local tests have also been conducted to determine the interfacial traction–separation laws in adhesively bonded joints. However, most of these local studies focused on the interfacial fracture between metal adherends. Limited studies have addressed the local test of interfacial fracture between laminated composite plates. While it was well known that the bondline thickness has an important effect on interfacial fracture, very few studies investigated its effects on the local interfacial traction–separation laws of laminated composite plates in the literatures. In this work, both global and local tests are employed to investigate the effect of bondline thickness on the interfacial energy release rate, interfacial strength, and shape of the local interfacial traction–separation laws. Basically, the measured laws in the present work reflect the equivalent and lumped interfacial fracture behaviors which include the cohesive fracture, damage and plasticity. The experimentally determined traction–separation laws provide valuable baseline data for parameter calibrations in numerical models. The experimental results may also facilitate the understanding of bondline thickness dependent delamination of composite structures.     

Chemical functionalization of composite surfaces for improved structural bonded repairs

In terms of lightweight design, aerodynamics and structural integrity, bonded repairs represent the preferred approach for repairing composite structures in aircraft applications. In this work the influence of crucial surface parameters including roughness, polarity and chemical composition on the performance of bonded repairs is studied. Besides mechanical and physical interactions, the study aims at the surface modification of carbon-fiber reinforced polymers (CFRP) to tailor chemical interactions with the adhesive. Reactive epoxy and mercapto derivatives are attached onto the CFRP surface by a 2-step functionalization route to ensure optimized adhesion and covalent bonding to epoxy-based adhesives. The performance of bonded coupon joints is determined by single lap shear tests (tensile-shear loading) and fracture mechanical tests (mode I loading). The results give evidence that chemical interactions play a key role in the quality of bonded repair systems. By controlling the chemical surface properties improved bond strength, homogenous crack growth and cohesive failure patterns are achieved.