Failure Load Prediction by Damage Zone Method for Single-lap Bonded Joints of Carbon Composite and Aluminum

A damage zone method based on 3D finite element analysis was proposed to predict the failure loads of single-lap bonded joints with dissimilar composite-aluminum materials. To simulate delamination failure, interply resin layers between any two adjacent orthotropic laminas of composite adherend were assumed with a thickness of one-tenth of a composite lamina. Geometrically nonlinear effects due to the large rotation of the single-lap joint were included in the analysis. Analysis also considered the material nonlinearity of the aluminum adherend due to the stress exceeding yield level. Based on the experimental observation that the failure modes of the specimens were dominated by delamination and debonding, the Ye-criterion was applied to account for the out-of-plane failure of composite adherend and the Von Mises strain criterion was applied for the adhesive layer. The failure indices were multiplied to the predicted damage zone as a weight factor and the calculated damage zones were divided by an area or volume considering the joint geometry. Predicted failure loads show deviation within 18% from experimental results for nine different bonding lengths or adherend thicknesses.

[1]  F. L. Matthews,et al.  Strength and failure modes of bonded single lap joints between cross-ply adherends , 1993 .

[2]  Liyong Tong,et al.  An Assessment of Failure Criteria to Predict the Strength of Adhesively Bonded Composite Double Lap Joints , 1997 .

[3]  Anthony J. Vizzini,et al.  The Inclusion of In-Plane Stresses in Delamination Criteria , 2001 .

[4]  J. D. Clark,et al.  Ultimate Tensile Stress over a Zone: A New Failure Criterion for Adhesive Joints , 1993 .

[5]  J. Kweon,et al.  A parametric study on the failure of bonded single-lap joints of carbon composite and aluminum , 2008 .

[6]  Lin Ye,et al.  Role of matrix resin in delamination onset and growth in composite laminates , 1988 .

[7]  M. M. Abdel Wahab,et al.  On the use of fracture mechanics in designing a single lap adhesive joint , 2000 .

[8]  H. Nakayama,et al.  Evaluation of the fatigue strength of adhesively bonded CFRP/metal single and single-step double-lap joints , 1999 .

[9]  Liyong Tong,et al.  Failure of adhesive bonded composite lap shear joints with embedded precrack , 2002 .

[10]  Nicholas J. Pagano,et al.  Interlaminar response of composite materials , 1989 .

[11]  Henry T. Y. Yang,et al.  Three-Dimensional Finite Element Analysis of Free Edge Stresses and Delamination of Composite Laminates , 1994 .

[12]  A. D. Crocombe,et al.  Global yielding as a failure criterion for bonded joints , 1989 .

[13]  J. K. Spelt,et al.  Failure load prediction of structural adhesive joints: Part 2: Experimental study , 1991 .

[14]  John Morton,et al.  Experimental and Numerical Studies of a Laminated Composite Single-Lap Adhesive Joint , 1995 .

[15]  John C. Brewer,et al.  Quadratic Stress Criterion for Initiation of Delamination , 1988 .

[16]  Marino Quaresimin,et al.  Life prediction of bonded joints in composite materials , 2006 .

[17]  A. Waas,et al.  Mixed-mode cohesive-zone models for fracture of an adhesively bonded polymer–matrix composite , 2006 .

[18]  Liyong Tong,et al.  A damage zone model for the failure analysis of adhesively bonded joints , 1998 .

[19]  Young-Jun Chun,et al.  Failure Load Prediction of Mechanically Fastened Composite Joints , 2003 .

[20]  H. L. Groth,et al.  Stress singularities and fracture at interface corners in bonded joints , 1988 .

[21]  Robert D. Adams,et al.  Strength Predictions for Lap Joints, Especially with Composite Adherends. A Review , 1989 .

[22]  David A. Dillard,et al.  A Stress Singularity Approach for the Prediction of Fatigue Crack Initiation in Adhesive Bonds. Part 1: Theory , 1999 .

[23]  Chun-Gon Kim,et al.  Failure prediction and strength improvement of uni-directional composite single lap bonded joints , 2008 .

[24]  J. Harris,et al.  Strength prediction of bonded single lap joints by non-linear finite element methods , 1984 .

[25]  M. Apalak,et al.  Progressive Damage Modeling of an Adhesively Bonded Unidirectional Composite Single-lap Joint in Tension at the Mesoscale Level , 2006 .

[26]  De Xie,et al.  Discrete cohesive zone model for mixed-mode fracture using finite element analysis , 2006 .

[27]  Kum Cheol Shin,et al.  Prediction of the tensile load-bearing capacity of a co-cured single lap joint considering residual thermal stresses , 2000 .