Prediction of the tensile load-bearing capacity of a co-cured single lap joint considering residual thermal stresses

In this paper, stress distributions in a co-cured single lap joint subjected to a tensile load were investigated using the finite element analysis. Residual thermal stresses, which resulted from the curing process of the co-cured single lap joint, were also considered. Since the adhesive layer in the co-cured single lap joint was about 10 μm thick, very thin compared with the thickness of both adherends, the interface between the steel and composite adherends was assumed to be perfectly bonded. The co-cured single lap joint was analyzed with respect to several bond parameters such as the bond length and stacking sequence of the composite adherend. The failure mechanism of the co-cured single lap joint was partial cohesive failure in the composite material, which was significantly affected by the interfacial tensile stress at the free edge of the co-cured single lap joint. Interfacial tensile stress was a primary factor that caused interfacial delamination between the steel and composite adherends in the co-cured single lap joint. Finally, tensile load-bearing capacities calculated from the Ye-delamination failure criterion were compared with the experimental results, and relatively good agreement was found.     

A study on the lap shear strength of a co-cured single lap joint

In this paper, the lap shear strength of a co-cured single lap joint subjected to a tensile load was investigated by experimental analysis. Co-cured joint specimens with several different bonding parameters such as bond length, surface roughness, and stacking sequence of the composite laminate were fabricated and tested. The dependence of the lap shear strength of the co-cured joint on the bonding parameters was investigated from the experimental results. The failure mechanism of the co-cured single lap joint was partially cohesive failure. The lap shear strength of the co-cured single lap joint was significantly affected by the bond length and the stacking sequence of the composite laminate. However, the effect of surface roughness on the lap shear strength of the co-cured single lap joint was not so significant.     

EFFECTS OF BOND PARAMETERS ON FATIGUE CHARACTERISTICS OF A COCURED DOUBLE LAP JOINT SUBJECTED TO CYCLIC TENSILE LOADS

A cocured joint whose manufacturing process is simpler than that of an adhesively bonded joint is attractive for composite structures due to its several benefits. Fatigue behavior in the cocured joint is important because under alternating loads it will fail at stress levels much lower than it can withstand under monotonic loading. Although some researchers have recently reported on cocured joints, there are only a few articles published on the fatigue characteristics of cocured joints. In this article, effects of bond parameters on fatigue characteristics of a steel-composite cocured double lap joint under cyclic tensile loads were experimentally investigated. In order to observe stress distributions near the interface edge of the cocured double lap joint, finite element analysis was also performed. We considered the surface roughness of the steel adherend and the stacking sequence of the composite adherend as bond parameters. A fatigue failure mechanism of the cocured double lap joint was explained systematically by investigating the surfaces of failed specimens and stress distributions at the interface edge. Failure criteria of the cocured double lap joint under cyclic tensile loads were shown graphically.     

Effects of bond parameters on fatigue characteristics of a cocured double lap joint subjected to cyclic tensile loads

A cocured joint whose manufacturing process is simpler than that of an adhesively bonded joint is attractive for composite structures due to its several benefits. Fatigue behavior in the cocured joint is important because under alternating loads it will fail at stress levels much lower than it can withstand under monotonic loading. Although some researchers have recently reported on cocured joints, there are only a few articles published on the fatigue characteristics of cocured joints. In this article, effects of bond parameters on fatigue characteristics of a steel-composite cocured double lap joint under cyclic tensile loads were experimentally investigated. In order to observe stress distributions near the interface edge of the cocured double lap joint, finite element analysis was also performed. We considered the surface roughness of the steel adherend and the stacking sequence of the composite adherend as bond parameters. A fatigue failure mechanism of the cocured double lap joint was explained systematically by investigating the surfaces of failed specimens and stress distributions at the interface edge. Failure criteria of the cocured double lap joint under cyclic tensile loads were shown graphically.     

Fatigue characteristics of a co-cured single lap joint subjected to cyclic tensile loads

In this paper, the effect of bond parameters on the fatigue characteristics of a steel-composite co-cured single lap joint under cyclic tensile loads was experimentally investigated. We considered the surface roughness of the steel adherend and the stacking sequence of the composite adherend as bond parameters. A fatigue failure mechanism of the co-cured single lap joint was explained systematically by investigating the surfaces of failed specimens.     

温度变化对复合材料双面搭接接头拉伸强度的影响分析

介绍了复合材料三种连接方式之一——胶接。对双面搭接接头进行了有限元建模,在不同的高温环境下进行拉伸试验,运用相关的失效准则,分析判断复合材料胶接接头的破坏形式,确定温度对破坏形式的影响。通过试验,验证了分析的正确性,对复合材料胶接接头的强度校核及设计改进有重要的指导作用。     

Experimental Analysis of the Bondline Stress Concentrations to Characterize the Influence of Adhesive Ductility on the Composite Single Lap Joint Strength

Adhesively bonded composite single lap joints were experimentally investigated to analyze the bondline stress concentrations and characterize the influence of adhesive ductility on the joint strength. Two epoxy paste adhesives—one with high tensile strength and low ductility, and the other with relatively low tensile strength and high ductility—were used to manufacture composite single lap joints. Quasi-static tensile tests were conducted on the single lap joints to failure at room temperature. High magnification two-dimensional digital image correlation was used to analyze strain distributions near the adhesive fillet regions. The failure mechanisms were examined using scanning electron microscopy to understand the effect of adhesive ductility on the joint strength. For a given surface treatment and laminate type, the results show that adhesive ductility significantly increases the joint strength by positively influencing stress distribution and failure mechanism near the overlap edges. Moreover, it is shown that high magnification two-dimensional digital image correlation can successfully be used to study the damage initiation phase in composite bonded joints.     

Progressive failure and experimental study of adhesively bonded composite single-lap joints subjected to axial tensile loads

Experimental tests and finite element method (FEM) simulation were implemented to investigate T700/TDE86 composite laminate single-lap joints with different adhesive overlap areas and adherend laminate thickness. Three-dimensional finite element models of the joints having various overlap experimental parameters have been established. The damage initiation and progressive evolution of the laminates were predicted based on Hashin criterion and continuum damage mechanics. The delamination of the laminates and the failure of the adhesive were simulated by cohesive zone model. The simulation results agree well with the experimental results, proving the applicability of FEM. Damage contours and stress distribution analysis of the joints show that the failure modes of single-lap joints are related to various adhesive areas and adherend thickness. The minimum strength of the lap with defective adhesive layer was obtained, but the influence of the adhesive with defect zone on lap strength was not decisive. Moreover, the adhesive with spew-fillets can enhance the lap strength of joint. The shear and normal stress concentrations are severe at the ends of single-lap joints, and are the initiation of the failure. Analysis of the stress distribution of SL-2-0.2-P/D/S joints indicates that the maximum normal and shear stresses of the adhesive layer emerge on the overlap ends along the adhesive length. However, for the SL-2-0.2-D joint, the maximum normal stress emerges at the adjacent middle position of the defect zone along the adhesive width; for the SL-2-0.2-S joint, the maximum normal stress and shear stress emerge on both edges along the adhesive width.     

An investigation into failure and behaviour of GFRP pultrusion joints

The paper investigates the failure and behaviour of metal/composite double lap shear (DLS) joints where the composite is the inner/loaded adherend, using multi-scale modelling techniques. The unidirectional (UD) composite is based on glass fibre and vinyl ester resin moulded by pultrusion. The multi-scale models include a long overlap DLS joint (macro), small shear and tensile laminate joints (meso) and fibre–matrix resin models (micro). The macro- and meso-scale joints/models were mechanically tested and numerically analysed to determine failure loads and corresponding stresses and to identify the loci of failure within the joint interfaces. In addition, the numerical modelling was extended to include micro-scale models to determine transverse tensile stresses at the fibre–matrix interface to further understand failure and behaviour. The study concluded that the failure in the bonded composite is largely governed by the maximum transverse strength at the fibre–matrix interface and its defects. Also, it was concluded that this stress might be suppressed by the longitudinal tensile stress acting on the UD composite at the surface just below the bondline.     

Characterising pre-preg and non-crimp-fabric composite single lap bonded joints

Pre-preg and non-crimp-fabric composite single lap bonded joints were manufactured and investigated to characterise the bond quality and static failure behaviour. A two-part epoxy adhesive was employed to bond composite laminates. The composite panels, which were treated with low pressure oxygen plasma, were bonded in a hot drape former and then cut to manufacture single lap bonded joints. The joints were examined using X-ray microtomography to evaluate the bond quality achieved in the hot drape former. Quasi-static tensile tests were conducted on the pre-preg and non-crimp-fabric composite single lap bonded joints. The fracture surfaces were examined using optical and scanning electron microscopy. The static failure behaviour and failure patterns observed in the two joint types were compared and discussed.     

Optimum design of co-cured steel–composite tubular single lap joints under axial load

In this paper, an optimum design method for co-cured steel-composite tubular single lap joints under axial load is proposed based on a failure model which incorporates the nonlinear mechanical behavior of the steel adherend and the failure mode of joints such as composite adherend failure and steel adherend failure. The design parameters considered were the test temperature, the stacking sequence of the composite adherends, the thickness ratio of the steel adherend to the composite adherend, and the existence of scarf in the steel adherend. Stress analysis of the cocured steel-composite tubular single lap joints was performed considering the nonlinear mechanical behavior of the steel adherend, and the fabrication residual thermal stress and thermal degradation of the composite adherend. The method developed may be employed in the joining of hybrid composite structures such as golf clubs and automotive composite propeller shafts in which a carbon/epoxy shaft has normally been bonded to a metal shaft with epoxy adhesives.     

The Torque Transmission Capabilities of the Adhesively-Bonded Tubular Single Lap Joint and the Double Lap Joint

With the wide application of fiber-reinforced composite materials in aircraft, space structures and robot arms, the design and manufacture of composite joints have become a very important research area because they are often the weakest areas in composite structures.

In this paper, the stress and torque transmission capabilities of the adhesively-bonded tubular single lap joint and the double lap joint were experimentally tested. In order to compare the experimental results with the calculated results, the stress and torque transmission capabilities were analyzed by the 3-dimensional finite element method taking into consideration the nonlinear properties of the adhesive.

From the experiments it was found that the torque transmission capabilities of the adhesively-bonded double lap joint was 2.7 times as large as that of the single lap joint. Also, it was found that the fatigue limit of the double lap joint was 16 times as large as that of the single lap joint.     

Influence of Fabrication Residual Thermal Stresses on Rubber-toughened Adhesive Tubular Single Lap Steel-Steel Joints under Tensile Load

The tensile load bearing capability of adhesively-bonded tubular single lap joints which is calculated under the assumption of linear mechanical adhesive properties is usually much less than the experimentally-determined because the majority of the load transfer of adhesively-bonded joints is accomplished by the nonlinear behavior of rubber-toughened epoxy adhesives. Also, as the adhesive thickness increases, the calculated tensile load bearing capability with the linear mechanical adhesive properties increases, while, on the contrary, the experimentally-determined tensile load bearing capability decreases.

In this paper, the stress analysis of adhesively-bonded tubular single lap steel-steel joints under tensile load was performed taking into account the nonlinear mechanical properties and fabrication residual thermal stresses of the adhesive. The nonlinear tensile properties of the adhesive were approximated by an exponential equation which was represented by the initial tensile modulus and ultimate tensile strength of the adhesive.

Using the results of stress analysis, the failure criterion for the adhesively-bonded tubular single lap steel-steel joints under tensile load was developed, which can be used to predict the load-bearing capability of the joint. From the failure criterion, it was found that the fracture of the adhesively-bonded joint was much influenced by the fabrication residual thermal stresses.     

Characterisation of GFRP surfaces amenable for bonding and their effect on the strength of co-cured vacuum resin infused single lap joints

The choice of a fabrication method is of primary importance in order to optimise and control the performance of composite materials. This becomes increasingly crucial when the fabrication method itself becomes in parallel an adhesive bonding co-cure technique. In this paper, the manufacturing process of the vacuum resin infusion jointing is introduced and specimens of co-cured single lap joints are fabricated and tested under a tensile load. The aim is to show the correlation between the surface characteristics of mechanically treated composite laminates and the adhesion performances of the corresponding surface assemblies using the vacuum resin infusion as a jointing procedure. The mechanisms that govern adhesion are investigated by measuring several physical and chemical parameters of the bonded surfaces with techniques such as surface profilometry, contact angle and surface energy measurements, X-ray photoelectron spectroscopy and scanning electron microscopy. These methods qualitatively and quantitatively measure the influence of surface characteristics towards adequate interfacial bond strength and reveal the importance of the mechanical interlocking, kinetics of wetting, chemical reactivity and intermolecular adhesion of the vacuum resin infusion joint interfaces. The results clearly demonstrate the major influence of the surface contamination and surface topography but also the role of the joining process itself, having no distinct adhesive layer, on the adhesion properties. It is shown that the interfacial adhesion qualities alter significantly the fragmentation process and the strength of the vacuum resin infused joints.     

The Static Failure of Adhesively Bonded Metal Laminate Structures: A Cohesive Zone Approach

Adhesively bonded metal laminates are used in aerospace applications to achieve low cost, light weight structures in the aerospace industry. Advanced structural adhesives are used to bond metal laminae to manufacture laminates, and to bond stringers to metal laminate skins. Understanding the failure behaviour of such bonded structures is important in order to provide optimal aircraft designs. In this paper, the static failure behaviour of adhesively bonded metal laminate joints is presented. A cohesive zone model was developed to predict their static failure behaviour. A traction–separation response was used for the adhesive material. Three joint configurations were considered: a doubler in bending, a doubler in tension and a laminated single lap. The backface strains and static failure loads obtained from experimental tests were used to validate the results from finite element modelling. The models were found to be in good agreement with experiments.     

Numerical study of lap joints with composite adhesives and composite adherends subjected to in-plane and transverse loads

In this paper, single lap joints for joining fibre composites were modeled and a three-dimensional finite element method was used to study the joint strength under in-plane tensile and out-of-plane loadings. The behaviour of all the members was assumed to be linear elastic. The adherends were considered to be orthotropic materials while the adhesive could be neat resin or reinforced one. The largest values of shear and peel stresses occurred near the ends of the adhesive region, as expected. The values and the rate of variation in peel stress was more than that of shear stress. By changing the properties and behaviour of adhesive from neat epoxy (isotropic) to fibre composite adhesive (orthotropic) and with various fibre volume fractions of glass fibre, the ultimate bond strength increased as the fibre volume fraction increased, in both tensile and transverse loadings. Also, changing the orientation of fibres in the adhesive region with respect to the global axes influenced the bond strength.     

Strength and interface failure mechanism of adhesive joints

Adhesive joints have a wide range of applications in the civil engineering, automotive and aircraft industries. In the present research, we use the finite element method to systematically study the overall strength and interface failure mechanism of single lap joints, which are subjected to tensile loading, focusing on the effects of various system parameters including fracture energy of the adhesive layer, overlap length and adhesive layer thickness on the load-bearing capability of the joints. The results show that the overlap length and the adhesive fracture energy have combined influences on the load-bearing capability. On the other hand, a preliminary damage analysis of the adhesive layer is carried out, considering the situations when the loads arrive to the peak values. Furthermore, the interface behavior is investigated, including the interface stress analysis and interface slip. The rotation of the joint during loading and its influence factors are studied as well. Obtained results suggest that the interface stress distributions are related to the slip and the rotation angle.     

An Experimental Study of the Static Torque Capacity of the Adhesively-Bonded Tubular Single Lap Joint

With the wide application of fiber-reinforced composite materials in aircraft, space structures and robot arms, the design and manufacture of composite joints have become a very important research area because they are often the weakest areas in composite structures. In this study, the effects of the adhesive thickness and tensile thermal residual stress on the torque capacity of tubular single lap joints were studied. The torque capacities of the adhesive joints were experimentally determined and found to be inversely proportional to the adhesive thickness. In order to match the experimental results to the theoretical analyses, the elastic-perfectly plastic material properties of the adhesive were used in the closed form solution. Also, the tensile thermal residual stresses of the joints were calculated by the finite element method and it was found that the thermal residual stresses could play an important role in the torque capacity when the adhesive thickness was large.     

Progressive Failure Analysis in Adhesively,Riveted, and Hybrid Bonded Double-Lap Joints

One of the important processes in structural design is the joining technique. Failure of composite joints involves different failure mechanisms depending upon the joining technique. In this study, a progressive failure analysis was performed on adhesively, riveted, and hybrid bonded double-lap joints. In the joints, a woven-type fiberglass-reinforced composite material was used as the main material; AV 2015 was used as the adhesive, and steel as the rivet material. The analyses were performed using ANSYS 12.1 finite element package software via software written using parametric design language (APDL) codes. At the end of the progressive failure analysis, failure loads and failure modes were determined for 30-, 45-, and 60-mm overlap lengths in accordance with the Maximum Shear Stress Theory and Hashin Criteria. For 45-mm overlap lengths, the joint strength of hybrid joints proved to be 2.72 and 1.145 times higher, respectively, than adhesive and fastening joints. Results showed that the failure load of the joint increased when the overlap length increased. In riveted joints, the failure occurring in the composite plates began around the rivet hole and the catastrophic failure of these types of joints resulted from fiber tensile failure.     

Thermal characteristics of tubular single lap adhesive joints under axial loads

When an adhesive joint is exposed to high environmental temperature, the tensile load capability of the adhesive joint decreases because both the elastic modulus and failure strength of the adhesive decrease. The thermo-mechanical properties of a structural adhesive can be improved by addition of fillers to the adhesive. In this paper, the elastic modulus and failure strength of adhesives as well as the tensile load capability of tubular single lap adhesive joints were experimentally and theoretically investigated with respect to the volume fraction of filler (alumina) and the environmental temperature. Also the tensile modulus of the filler containing epoxy adhesive was predicted using a new equation which considers filler shape, filler content, and environmental temperature. The tensile load capability of the adhesive joint was predicted by using the effective strain obtained from the finite element analysis and a new failure model, from which the relation between the bond length and the crack length was developed with respect to the volume fraction of filler.