Abstract
Double strap lap adhesive joints between metal (AA 6061-T6) and composite (carbon/epoxy) laminates were fabricated and characterized based on strength. Hand layup methods were used to fabricate double strap match lap joints and double strap mismatch lap joints. These joints were compared for their strength under static and fatigue loadings. Fracture toughness (GIIC) was measured experimentally using tensile testing and validated with numerical simulations using the cohesive zone model (CZM) in ABAQUS/Standard. Fatigue life under tension–tension fluctuating sinusoidal loading was determined experimentally. Failure loads for both joints were in close relation, whereas the fatigue life of the double strap mismatch lap joint was longer than that of the double strap match lap joint. A cohesive dominating failure pattern was identified in tensile testing. During fatigue testing, it was observed that inhomogeneity (air bubble) in adhesive plays a negative role while the long time duration between two consecutive cycle spans has a positive effect on the life of joints.
Highlights
Fiber metal laminates (FMLs) basically fall in the category of hybrid composites, consisting of alternating layers of metal alloy sheets such as aluminum and fiber-reinforced epoxy such as carbon/epoxy
Plain-woven carbon fabric, which is used as a strap material [41], was used to make carbon-reinforced aluminum laminate (CARALL) composites
This study focuses on the relationship between the strength of a double strap joint and the novel orientation of plain-woven carbon fiber straps on an aluminum 6061-T6 plate and the comparison with the strength of a traditional double strap match
Summary
Fiber metal laminates (FMLs) basically fall in the category of hybrid composites, consisting of alternating layers of metal alloy sheets such as aluminum and fiber-reinforced epoxy such as carbon/epoxy. This research work involves the fabrication and experimental tensile and fatigue testing of double strap lap adhesive joint (match and mismatch) between metal and composite (aluminum alloy 6061-T6 metal with carbon/epoxy composite laminates) and validation with simulation results. One is related to the carbon fiber orientation (woven) in carbon/epoxy laminates while the other is related to the comparison between double strap (match and mismatch) geometry configuration These configurations were fabricated using the hand layup technique, which is quite economical, rather than manufacturing through autoclaves. Plain-woven carbon fabric, which is used as a strap material [41], was used to make carbon-reinforced aluminum laminate (CARALL) composites It has high tensile strength and continuous fiber with 3000 filament tows in the present case [42]. Surface preparation is necessary to obtain good bonding between epoxy and Al sheets [44–46]
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