搭接长度对CFRP单搭接胶接接头拉伸性能及破坏特征的影响

采用碳纤维增强复合材料(CFRP)基板制备不同搭接长度的单搭接胶接接头,并利用数字图像相关方法(DIC)、万能电子试验机等测试手段,对胶接接头失效载荷、断裂过程和应变场变化等进行表征,研究搭接长度对单搭接接头拉伸性能、断裂过程、应变分布以及破坏特征的影响.结果表明:随搭接长度增加,接头平均剪切强度先明显降低,后趋于稳定.拉伸过程中由偏心载荷所引起的接头次弯曲效应愈加显著,搭接区域端部变形程度逐渐增大,接头初始破坏位置由搭接区域端部中的一端向两端转变.接头正面和侧面端部的应变集中区域由非对称分布向对称分布过渡.接头受剥离力逐渐增大,层间主要失效形式由剪切向剥离破坏转变,接头破坏模式经历了由界面和轻微纤维撕裂到混合失效再到层间分层的过程.     

钢/铝CMT接头熔合面积对接头抗剪强度及破坏模式的影响

针对低碳镀锌钢板与6061铝合金CMT熔钎焊接头熔合面积对其抗剪强度和破坏模式的影响进行研究。结果表明:熔钎焊过程中,随着焊枪相对于搭接接头中心线偏移量的增大,接头的熔合面积逐渐减小,润湿角增大,进而导致接头的抗剪强度逐渐减小,接头的断裂位置由铝熔合区破坏向钢/铝界面层破坏转变。根据实验结果,考虑界面层的失效判据,建立CMT接头拉剪过程的数值模型,讨论熔合面积影响接头抗剪强度及破坏模式的原因。     

胶层厚度对碳纤维/双马来酰亚胺树脂复合材料平-折-平混合连接接头力学性能的影响

以碳纤维/双马来酰亚胺(BMI)树脂复合材料平-折-平(FJF)连接接头为对象,通过试验对比分析了特定胶层厚度下碳纤维/BMI树脂复合材料FJF连接接头的静强度和疲劳性能,并探究了胶层厚度对碳纤维/BMI树脂复合材料FJF混合接头力学性能的影响。利用背面应变技术对碳纤维/BMI树脂复合材料FJF混合接头搭接区端部胶层开裂进行监测。利用有限元软件ABAQUS对不同胶层厚度下碳纤维/BMI树脂复合材料FJF混合接头搭接区胶层应力分布进行了分析。结果表明,碳纤维/BMI树脂复合材料FJF混合接头的平均拉伸极限载荷、搭接区端部胶层开裂平均循环次数和平均疲劳寿命均随着胶层厚度在0.1~0.3 mm范围内增加而增大。不同胶层厚度的碳纤维/BMI树脂复合材料FJF混合接头均经历相同的失效阶段,即搭接区胶层端部开裂,胶层沿搭接区断裂扩展,最终靠近加载端孔边拉伸断裂,呈±45°断口。随着胶层厚度在0.1~0.3 mm范围的增加,搭接区端部胶层剥离应力、剪切应力及孔边胶层压缩应力均减小。在胶层厚度为0.1~0.3 mm范围内,剪应力是胶层破坏的控制因素。      

FRC/钢燕尾槽单向连接结构强度特性及损伤机理

针对纤维增强复合材料(FRC)与钢结构的紧密坚固连接要求,提出并设计了FRC/钢结构燕尾槽单向嵌入式胶接连接结构形式.初步设计的连接结构试件单向面内抗剪极限强度试验测试结果显示:由于层间剪力引起的自由端效应影响,FRC/钢燕尾槽连接结构的初始损伤将最先出现在自由端部,导致连接结构紧密性连接要求不能得到满足,而槽体连接区内纤维的层间分层和拐角区树脂基体的挤压损伤以及上下层间界面剥离构成了燕尾槽单向连接结构抗剪承载时的典型损伤及破坏模式.为此,提出了自由端部增强改进结构形式.采用有限元数值方法(Abaqus/Standard)对改进前、后两种连接结构界面应力分布特性进行分析,改进结构试验研究结果表明:改进后单向燕尾槽连接结构层间界面应力分布更趋合理,自由端部分层初始损伤得到有效抑制,燕尾槽单向连接结构能在有效保证水密性要求的前提下,使抗剪极限强度提高约61%.     

铺层顺序对预成型体搭接复合材料拉伸性能影响的仿真与验证

使用有限元理论模拟分析了几种不同铺层顺序的预成型体搭接复合材料的拉伸性能,并且使用国产碳纤维与快速固化环氧树脂制备相应的单下陷搭接试样,测试其搭接接头的拉伸性能,对有限元计算结果进行了验证。结果表明,使用有限元计算与实验方法得到的结果基本相符。有限元模拟及实验验证发现不同铺层结构的预成型体搭接复合材料有两种不同的破坏损伤模式。搭接上层板的层间剥离强度与层板本身弯曲性能共同决定了搭接接头的破坏模式及拉伸性能,两者中强度较弱的先发生破坏,导致试样失效。在预成型体搭接接头中,0°铺层越靠近搭接面,对搭接性能的影响越明显,搭接强度越高。搭接界面处纤维层之间的相对角度不同,纤维铺层刚度不同,刚度差别越大,搭接强度就越低。     

润滑油对钢板胶接强度及环境腐蚀性能的影响

本文针对裸钢板及其涂润滑油的钢板表面进行接触角测试、表面自由能计算,进而研究润滑油对其界面粘合功与接头强度的影响;并在此基础上,分析润滑油对钢板单搭胶接接头在水浴环境中的抗腐蚀性能影响。结果发现:润滑油极大地提高了钢板与胶粘剂间界面结合能中的极性分量,从而略微提高了钢板胶接接头强度,改善了接头失效模式。在水浴环境下,由于扩散到界面处的水分子对氢键的破坏及对极性分子的溶解,接头强度急剧下降,界面失效面积增加。润滑油主要增加了界面结合能中极易被水分子破坏的极性分量,因而对钢板胶接接头水浴环境腐蚀性能影响较小。     

基于循环载荷的单搭胶接接头残余强度分析

为研究循环载荷下单搭胶接接头的残余强度及失效机理,以5052铝合金单搭胶接接头为研究对象,先后对其进行静强度测试、疲劳强度测试和残余强度测试,引入威布尔分布对试验数据进行分析,检验其有效性,并采用超声扫描显微镜和扫描电子显微镜对失效胶层进行失效机理分析。结果表明,在疲劳循环载荷作用下,接头刚度基本稳定,而残余强度随着疲劳循环载荷周次的增加,呈现出先增大后减小的变化趋势;疲劳裂纹从接头搭接端部的界面端点处开始萌生,并快速向中间扩展,当疲劳循环达到一定次数时,胶层瞬间断裂,裂纹萌生阶段几乎占据了其全部疲劳寿命,失效后的胶层会出现"凹台"状微观结构。     

搭接区端部细观结构对受拉复合材料单搭接头力学响应的影响

在复合材料单搭接头的加工过程中,在搭接区端部会形成一些细观结构,从而在这些区域常存在比较严重的应力集中。应用实验和有限元方法研究了胶瘤和复合材料端部毛刺这2 种搭接区端部细观结构对受拉复合材料层合板单搭接头力学响应的影响。应用数字图像相关方法测量了搭接区端部的应变场分布情况,同时利用基于子模型技术的非线性有限元方法分析了搭接区端部细观结构的作用。实验结果与有限元分析结果吻合较好。实验和有限元结果都表明胶瘤分担了部分载荷,可以降低搭接区端部的应力集中。复合材料端部毛刺的作用与毛刺的具体结构关系密切,不同结构的毛刺对搭接区端部应力应变分布的影响是不同的。     

复合材料导弹易碎盖薄弱区的弯曲性能

为研究复合材料导弹易碎盖薄弱区的承弯性能,制作了单搭接对接(胶接)和双搭接对接(胶接)试验件,进行了四点弯曲试验,研究了不同搭接长度对胶接接头弯曲破坏载荷的影响。同时,建立了复合材料单、双搭接接头的三维有限元模型,进行了弯曲载荷下的渐进损伤分析。层合板采用UMAT用户子程序编写的本构关系描述,胶接界面采用粘聚区模型进行模拟。引入合适的损伤起始和扩展准则,预测了接头的弯曲强度。仿真结果和实验结果吻合较好,表明受拉面搭接板长度的增加一定程度上提升了接头的抗弯性能,而受压面搭接板对于接头的强度影响不大。     

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。      

Optimum thickness of joints made of GFPR pultruded adherends and polyurethane adhesive

This paper presents results of experimental and numerical investigations on double-lap joints composed of pultruded GFRP profiles and polyurethane adhesive subjected to quasi-static axial tensile loading. The objective was to investigate the effect of the joint geometry on the structural response of adhesively-bonded joints and, in particular, to seek for experimental evidence of an optimum adhesive layer thickness. The influence of the adhesive thickness (0.3–10.0 mm) and the overlap length (50–200 mm) on the joint behavior was investigated. It was found that there is an optimum adhesive thickness of approximately 1.0 mm and joint strength consistently increases with the overlap length.     

Fatigue performance of metallic reverse-bent joints

Adhesively bonded lap shear joints have been investigated widely and several ideas have been proposed for improving joint strength by reducing bondline stress concentrations. These include application of adhesive fillets at the overlap ends and use of adhesive with graded properties in the overlap area. Another, less common, approach is to deform the substrates in the overlap area in order to obtain a more desirable bondline stress distribution.
Previous work carried out by the authors on a number of different substrate materials indicated that a reverse-bent joint geometry is useful for increasing joint strength. Results from static stress analysis and experimental testing demonstrated that significant improvements could be achieved. This paper presents results of further work carried out to assess the fatigue performance of reverse-bent joints. Substrates with different yield and plastic deformation characteristics were used and the effects of different overlap lengths on strength were examined. The results of this research show that the improvements obtained under static tests conditions translate to even higher benefits in fatigue. The paper also explains the failure mechanism of the joints under fatigue loading.     

Fast failure prediction of adhesively bonded structures using a coupled stress‐energetic failure criterion

The use of adhesively bonded joints in industrial structures requires reliable tools for the estimation of the failure load. The necessary and sufficient condition to predict the strength of such joints involves the implementation of a coupled stress and energetic criteria. However, its application necessitates the identification of the stress distribution along the adhesive layer, which has been approximated in this paper by a previously published closed‐form solution. This analysis along with finite element modelling results are compared with experimental data issued from a double‐notched sample tested with the Arcan fixture at various load ratios. The results show good agreement; the use of the closed‐form solution permitted to predict the failure load more rapidly and in a conservative manner compared with the experimental results. The application of the methodology is also extended to a wider range of joint geometries by means of spatial interpolation using the Kriging model.     

A parametric study on the failure of bonded single-lap joints of carbon composite and aluminum

A parametric study on adhesively bonded carbon composite-to-aluminum single-lap joints was experimentally conducted. FM73m, a high strength adhesive produced by Cytec, was used for bonding. The primary objective of this study is to investigate the effects of various parameters, such as bonding pressure, overlap length, adherend thickness, and material type, on the failure load and failure mode of joints with dissimilar materials. While metal bonded joints generally fail at the adhesive, the final failure mode of all the tested bonded joints with dissimilar materials was delamination of the composite adherend. Bonding strengths of the tested joints were lower than the metal-to-metal bonded joint strength. The specimens bonded under pressure of 4 and 6 atm yielded higher failure loads than under pressure of 3 atm, which is within the range of the manufacturer-recommended bonding pressure. Failure loads of the joint increased slightly at an overlap length larger than 30 mm. Increasing adherend thickness resulted in an increase of the failure load, but was not linearly proportional to the failure load.     

扩展有限元方法与内聚力模型耦合下斜接修补复合材料的胶层损伤和缺陷

将扩展有限元方法（XFEM）与内聚力模型（CZM）耦合用于斜接修补复合材料的胶层分析,实现了对复合材料与修补胶层之间的脱粘以及胶层内部裂纹扩展现象的描述,模拟得到的结构强度与试验结果吻合较好。对复合材料与胶层的界面缺陷和胶层内部缺陷展开分析,讨论了缺陷长度和缺陷位置对结构强度的影响。结果表明：在相同条件下,结构具有界面缺陷比具有胶层内部缺陷更加危险;结构强度受缺陷长度和与缺陷尖端相邻复合材料铺层角度的共同影响,随着缺陷长度的增加而降低,降低速率大于缺陷长度增长比例;当缺陷位置不同时,结构强度主要与缺陷对应位置的平均剪应力水平相关。最后,通过参数分析讨论了界面剪切强度的影响。     

Impact rupture of structural adhesive joints under different stress combinations

The paper reports the results of an experimental study on bonded joints, carried out by means of an instrumented impact pendulum, equipped to load overlap specimens in shear. Such testing configuration is the most adequate and natural to study the possible modifications of the behavior of the joint, changing from static to dynamic loading condition, keeping the same specimen type. The specimens were steel strips bonded by an epoxy adhesive (Hysol 3425). Several values of lap length, adhesive and adherends thickness were adopted, to achieve rupture under different peel and shear stress combinations. The stress state at rupture has been calculated by means of a structural solution. The results show that the failure points, in a chart having as axes the maximum values of peel and shear structural stress, lie outside the rectangular limit zone previously obtained under static conditions. Therefore, in spite of the concerns associated with the impact condition, the strength of the tested adhesive does not decrease with respect to the case of static loading. In alternative, also the evaluation of the stress intensity factor proves to be effective to predict failure in the considered cases.     

碳纤维增强树脂基复合材料层合板胶螺混合连接失效机制

为研究碳纤维增强树脂基复合材料(CFRP)层合板单搭接双螺栓胶螺混合连接失效机制,采用基于断裂能断裂准则的连续渐进退化方式,仿真CFRP层合板刚度退化,采用基于能量的B-K准则仿真胶层的损伤演化,建立胶螺混合连接结构渐进损伤三维有限元模型,有限元模型预测的最大失效载荷与实验结果吻合较好。搭接长度L_a为影响胶螺混合接头刚度和强度的重要几何参数,螺栓的位置不会明显影响接头的刚度,粘结面积越大,强度越大。胶螺混合接头在拉伸载荷作用下,由于二次弯曲效应的影响,螺栓向左倾斜,搭接区域的胶层损伤起始于搭接区域胶层外侧,并由外侧向内部扩展到钉孔附近,当胶层损伤扩展到钉孔附近时,螺栓承载增加,胶层和螺栓共同承载,此时CFRP层合板开始出现损伤;最终,左侧钉孔处的上层合板和右侧钉孔处的下层合板产生分层损伤并发生断裂。      

Failure mode and strength of uni-directional composite single lap bonded joints with different bonding methods

Failure process, mode and strength of unidirectional composite single lap bonded joints were investigated experimentally with respect to bonding methods, that is, co-curing with or without adhesive and secondary bonding. The co-cured joint specimen without adhesive had the highest failure strength. Progressive failures along an adhesive layer occurred in the secondary bonded specimen. In the co-cured specimen with adhesive film, delamination failure occurred and the joint strength was lower than that of secondary bonded specimens. Delamination failure did not occur in the secondary bonded specimen because of early crack growth and progressive failure in the adhesive layer. Therefore, The failure strength of composite bonded joint is not always proportionate to adhesion strength of adhesive due to the weakness of delamination in composite materials. The influences of surface roughness, bondline thickness and fillets in the secondary bonded specimens were also studied.     

Experimental and numerical evaluations on the effects of adhesive fillet,overlap length and unbonded area in adhesive‐bonded joints

To realize robust structural design, the effects of the adhesive fillet, overlap length and unbonded area in adhesive‐bonded joints need to be fully understood and incorporated into a fatigue life estimation method. In the present work, both static and fatigue experiments are performed on six types of adhesive‐bonded joints to illuminate these effects systematically. A straightforward total fatigue life evaluation method is proposed to address these effects. A statistical crack initiation model is established based on the fatigue data of bulk adhesive specimens. Growth life is calculated using the interfacial crack model and mixed mode crack growth method. Good correlation is observed between the calculated and experimental fatigue lives. Furthermore, the effects of the adhesive fillet, overlap length and unbonded area are analysed based on both calculated and experimental results. Results indicate that adhesive fillet postpones crack initiation by reducing local strain level, both overlap length and unbonded area change the growth life by length. Besides, overlap length promotes the fraction of mode II strain energy release rate in total, reducing crack growth rates and extending growth life.