Abstract
A stress analysis technique has been developed for load transfer in metal-to-composite adhesively bonded step-lap joints with bondline flaws. The problem is formulated based on the assumptions that both the metal and the composite are under generalized plane stress condition and that the adhesive acts as a shear spring. A set of differential equations is obtained for the load transferred from the metallic layer to the composite. Two types of bondline flaws are considered: debonds in the adhesive and gaps between step ends. The differential equations together with the appropriate boundary conditions are solved for each case. Numerical results are presented for force and nominal stress in the composite layer, stress in the metal, and shear stress in the adhesive.
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