Stress Distributions in Brazed Single-Lap Joints Under Tensile Loading

Abstract

The most common method for characterizing the strength of brazed joints is uniaxial tension testing of single lap joints (SLJs). Standard interpretations depend on the assumption that the average shear stress at failure is the key metric in determining joint strength. However, it is evident from the geometry that the stress distributions must be inhomogeneous with shear lag type stress concentrations at the ends of the overlap regions. Eccentric loading causes overlap rotation and bending stresses that amplify the stress concentrations and result in geometric nonlinearity. Unfortunately, details of the distributions of normal and shear stresses on the braze needed to understand failure have not been presented. Thus, finite element analysis was used to quantify these stress distributions using 2D elastic and elasto-plastic models of monolithic stainless steel SLJs. Bending stresses and normal and shear stresses acting on the braze were determined over a wide range of overlap ratios and applied stresses. For all conditions, stresses are highly concentrated in a narrow region at overlap ends with peak normal stresses exceeding peak shear stresses. Variations in peak stresses with applied stress and overlap ratio were found to fully explain experimental joint strength data. Common interpretations based on the average shear stress at failure are found to be incorrect. Implications for testing, interpretation, and joint design are discussed.