Biomimetic-inspired joining of composite with metal structures: A survey of natural joints and application to single lap joints

Joining composites with metal parts leads, inevitably, to high stress concentrations because of the material property mismatch. Since joining composite to metal is required in many high performance structures, there is a need to develop a new multifunctional approach to meet this challenge. This paper uses the biomimetics approach to help develop solutions to this problem. Nature has found many ingenious ways of joining dissimilar materials and making robust attachments, alleviating potential stress concentrations. A literature survey of natural joint systems has been carried out, identifying and analysing different natural joint methods from a mechanical perspective. A taxonomy table was developed based on the different methods/functions that nature successfully uses to attach dissimilar tissues (materials). This table is used to understand common themes or approaches used in nature for different joint configurations and functionalities. One of the key characteristics that nature uses to joint dissimilar materials is a transitional zone of stiffness in the insertion site. Several biomimetic-inspired metal-to-composite (steel-to-CFRP), adhesively bonded, Single Lap Joints (SLJs) were numerically investigated using a finite element analysis. The proposed solutions offer a transitional zone of stiffness of one joint part to reduce the material stiffness mismatch at the joint. An optimisation procedure was used to identify the variation in material stiffness which minimises potential failure of the joint. It was found that the proposed biomimetic SLJs reduce the asymmetry of the stress distribution along the adhesive area.