Double Lap Shear Research Articles

Experimental and numerical investigations about the combined effect of interference fit and bolt clamping on the fatigue behavior of Al 2024-T3 double shear lap joints

In this paper the fatigue behavior of double shear lap joints treated by different combinations of interference fit and bolt clamping have been investigated both experimentally and numerically. To do so, specimens made from aerospace structural material of aluminum alloy 2024-T3 plates were interference fitted at the sizes of 1.5% and 4.7% and torque tightened with 2 and 4 N m to be prepared for fatigue tests. Consequently, the joints were subjected to cyclic load at different levels to obtain fatigue life. Finite element (FE) analysis was also performed to find the stress and strain distributions and the results were used to help explain the trends observed in the experimentally obtained S–N data. The experimental tests showed that during the interference fit process a protruded region is created at around the hole in the exit plane due to directional material plastic flow as a consequence of the oversized bolt force fitting. This protruded region has a bigger height for the bigger interference fit size. The finite element results showed that the protruded region generally localizes the compressive effect of bolt clamping and reduces its capability in fatigue life enhancement, by relaxing the clamping force. The fatigue test results showed that a better fatigue life improvement was achieved by employing the combination of a smaller interference fit size and bigger clamping force.

An experimental investigation of the bolt clamping force and friction effect on the fatigue behavior of aluminum alloy 2024-T3 double shear lap joint

In this article, the effect of bolt clamping force on the fatigue life of bolted double shear lap joints was investigated. To do so, fatigue tests were carried out on the bolt clamped double shear lap joint specimens made of aluminum alloy 2024-T3. These fatigue tests were conducted with applied torques of 0.25, 2 and 4 N m at different cyclic longitudinal load levels in un-lubricated and lubricated states. From these tests the stress–life ( S– N) data for different clamping forces for un-lubricated and lubricated states were obtained. The results show that clamping force increases fatigue life compared to clearance fit specimens. In general, at higher tightening torque higher fatigue lives were achieved, however, below a certain load level the life improvement was discontinued because of fretting phenomenon. Also lubricating the parts of the specimens reduces the advantage of clamping force or torque tightening.

Fabrication, testing and analysis of steel/composite DLS adhesive joints

This paper describes experimental and numerical techniques to study the structural design of double lap shear joints that are based on thick-adherend steel/steel and steel/composite, with epoxy adhesive. A standard practical fabrication method was used to produce specimens of various dimensions and materials. These specimens consist of 10 mm steel inner adherend and various outer adherend materials including composite and steel of various thicknesses and overlaps. The composite is largely based on carbon fibre-reinforced plastic. The specimens were tested under monotonic tensile loading and the results showed that joint strength depends largely on materials combination and overlap length. The testing also included the use of an advanced imaging system to determine failure initiation and propagation. Two-dimensional finite element analysis (FEA) stress models were applied and showed the importance of modelling the composite layers adjacent to the adhesive bondline in order to account for the critical local stresses. The FEA results also showed that overall shear stress distributions can be used to characterise joint failure. The paper presents the experimental and numerical details with key conclusions.

Investigation of creep effects in strengthened RC structures through double lap shear testing

The creep effects in RC strengthened structures are studied through measurements in double lap shear tests and numerical results. The experimental results were obtained from an original test procedure and measurement device. Short-term tests were performed at different temperatures and results were checked by means of long-term tests using the WLF theory and the time–temperature principle. In the second part of the paper, a numerical model is proposed based on an incremental form of the linear viscoelasticity theory and the FE method. Numerical results were compared with test data and a parametric study was carried out. These results show that the proposed model allows a prediction of time-dependent response of the double lap shear test specimen and the stress redistribution occurring between the different materials, along the bonding joint and through the width of the specimen.

Experimental investigation of the shear dynamic behavior of double-lap adhesively bonded joints on a wide range of strain rates

The main concern of this work is the mechanical characterization of adhesively bonded assemblies under dynamic shear loading ranging from quasi-static (10 −4 s −1) up to high (10 4 s −1) strain rates. The double-lap shear sample is proposed and a bonding procedure is established. The assemblies are made of steel substrates bonded with an epoxy adhesive. Two surface treatments of the substrates are considered: ethanol and sand shooting. The shear strength and the failure strain are measured by taking into account the testing setups accuracy and the non-uniform distribution of the stress and strain fields in the overlap region. The sensitivity of the strength and the failure strain to the strain rate is highlighted; it is found that the failure strain decreases and the shear strength increases with the strain rate until reaching a maximum value then it drops for very high strain rates.

Experimental Investigation on Effective Bond Length of Flexurally CFRP-Strengthened RC Beams Failed by Intermediate Crack Debonding

The models to calculate the effective bond length determined by single-lap or double-lap shear tests are more suitable for the end-debonding failure; and the improved models based on the simply shear test models to calculate the effective bond length of flexural CFRP-strengthened beams failed by intermediate crack debonding (IC debonding) are also lack of the support of experimental data. To investigate the effective bond length of flexural CFRP-strengthened beams, a total of 9 flexurally CFRP-strengthened beams were tested. The experimental results show that the existing models are very conservative for calculating the effective bond length in flexural FRP-strengthened RC beams failed by IC debonding. Based on the experimental results, this paper presents a model to calculate the effective bond length of flexural FRP-strengthened RC beams failed by IC debonding, and a model to calculate the plastic hinge length at the shear-flexure span.

Environmental durability of a CFRP system for strengthening steel structures

Recently a high modulus CFRP system was developed to enhance the load carrying capacity and serviceability of steel bridges and structures. However, the environmental durability of the system has not yet been demonstrated. This paper presents the findings of a research program that was conducted to evaluate the environmental durability of the bond of the proposed CFRP strengthening system to steel surfaces. The program consisted of testing 44 steel-CFRP double-lap shear specimens. The specimens were exposed to severe environmental conditions for different durations, up to 6 months. Different methods to enhance the bond durability were studied including pre-treating the steel surface with a silane coupling agent, inserting a glass fiber layer within the adhesive and a combination of both methods of protection. The research findings indicate that the use of a silane coupling agent significantly enhanced the bond durability. While the presence of the glass fibers helped to enhance the initial bond strength of the system, it did not improve the durability of the bond. The use of both techniques enhanced both the overall bond strength and the environmental durability of the strengthening system.

Experimental and numerical investigation of the influence of imperfect bonding on the strength of NCF double-lap shear joints

The influence of imperfect bonding, owing to partial lack of adhesive, on the strength of composite non-crimp fabric (NCF) double-lap shear (DLS) joints was experimentally and numerically investigated. Fabrics were layered and compacted using a thermoplastic veil while infiltration of the preforms was done using the vacuum assisted process. Paste adhesive bonding was carried out by implementing the novel insertion squeeze flow process. Quality of adhesive bonding was tested using X-ray imaging and ultrasonic C-scan inspection. The tensile lap shear strength of the DLS joints was determined experimentally. Digital macrographs revealed that the specimens failed due to shear failure of the adhesive (debonding) and fracture of the composite boundary layer. As a second approach, a mesomechanical model based on the FE method and the (homogenized) progressive failure analysis method was developed. In the model, the areas without adhesion, as detected by the C-scans, were included. Numerical simulations of failure initiation and progression at the NCF joint and the adhesive indicated that it is possible to predict the strength and failure mechanisms of the imperfect bonded DLS joints.

Global and Local Fiber Optic Sensors for Health Monitoring of Civil Engineering Infrastructure Retrofit with FRP Materials

Fiber-reinforced polymer (FRP) materials are currently used for strengthening civil engineering structures and bridges. The effectiveness of the strengthening system is highly dependent on the bond characteristics of the FRP material to the external surface of the structure. This article presents the application of two types of fiber optic sensors, which can be embedded in FRP materials to monitor the global and local behavior of the strengthened structure, respectively. The global sensor is designed to evaluate the overall condition of a structure based on the measured elongation of the FRP layer along the entire span of the structure. The success of this low-cost global sensor has been demonstrated using a full-scale prestressed concrete bridge girder that was loaded up to failure. The test results indicate that this type of sensor can be used to identify major changes in the overall behavior of the structure such as cracking of prestressed members or yielding of the internal reinforcement. The second sensor component consists of fiber Bragg grating sensors. The sensors were used to monitor the behavior of steel double-lap shear specimens tested under tensile loading up to failure. The measurements were used to identify abnormal structural behaviors such as epoxy cracking and/or FRP debonding. The test results compared well to the numerical values obtained from a three dimensional shear-lag model that was previously developed to predict the sensor response.

Theoretical Solution for Fatigue Debonding Growth and Fatigue Life Prediction of FRP-Concrete Interfaces

This paper presents an analytical solution for the evolution and distribution of shear stresses along the entire bond length of FRP-concrete interfaces due to mode-II fatigue loading. The creep-fatigue interaction and fatigue crack growth after debonding initiation are incorporated into a nonlinear interfacial constitutive law. While the creep-fatigue interaction is represented by the degradation of the interfacial stiffness, the debond growth is governed by a form of the Paris equation and the fracture energy ratio, Gmax/Gc. Furthermore, a new form of energy ratio is adopted to be debond-dependent. Through a series of experimental double-lap shear specimens, the results showed that the debond growth rate ( da/dN) along the FRP-concrete interfaces diminishes with fatigue cycles and that 30% of the static bond capacity of the FRP-concrete interface can be considered as the endurance limit of fatigue loading for FRP-strengthened beams. The agreement between the theoretical predictions and experimental results is valid, with a good degree of accuracy.

Constitutive and Aging Behavior of Sn3.0Ag0.5Cu Solder Alloy

We describe double-lap shear experiments on Sn3.0Ag0.5Cu solder alloy, from which fits to Anand's viscoplastic constitutive model, power-law creep model, and to time-hardening primary-secondary creep model are derived. Results of monotonic tests for strain rates ranging from 4.02E-6 to 2.40E-3 s-1, and creep response at stress levels ranging from 19.5 to 45.6 MPa are reported. Both types of tests were conducted at temperatures of 25degC, 75degC , and 125degC. Following an earlier study where Anand model and time hardening creep parameters for Sn3.8Ag0.7Cu and Sn1.0Ag0.5Cu solder alloys were reported, here we report power law model parameters so as to enable a comparison between all three alloys. Primary creep in Sn3.0Ag0.5Cu solder alloy is shown to be significant and are considered in addition to secondary creep and monotonic behavior. Aging influence on behavior is also shown to be significant. On the basis of experimental data, the following four aspects are discussed: 1) difference between testing on bulk versus joint specimen; 2) consistency between the creep and monotonic behaviors; 3) comparison against behaviors of Sn1.0Ag0.5Cu and Sn3.8Ag0.7Cu alloys as well as aganist Sn40Pb, 62Sn36Pb2Ag and 96.5Sn3.5Ag alloys; and 4) comparison of Sn3.0Ag0.5Cu and Sn3.8Ag0.7Cu relative to their aging response.

Effect of hole lubrication on the fretting fatigue life of double shear lap joints: An experimental and numerical study

In this research the affect that lubrication at a hole and pin connection has on the fatigue life of a double shear lap joint is studied both experimentally and numerically. The study focuses on the joint middle plate item, which is connected via a central hole to the outer plates by means of a clearance fitting pin, thereby placing the hole in double shear. In the experimental work three identical batches of fatigue specimens, which are made from aluminum alloy 2024-T3, were fatigue tested. In the first batch the surface of the fastener hole was not lubricated whilst the hole in the other two batches was lubricated – each batch using a different lubricant. The three batches of double shear lap joint specimens were fatigue tested and their S– N curves established. The results show that the specimens in which the holes were lubricated have better fatigue lives than the non-lubricated hole specimens. In the numerical study, FE simulations were performed to include hole lubrication effect on the stress distribution by using different friction coefficient at the interface of the hole and its fastener (pin). The FE results have helped to gain an understanding of the reasons for fatigue life improvement and also have helped to quantify the level of improvement.

Prediction of long term strength of adhesively bonded steel/epoxy joints in sea water

This study is concerned with the development of a tool to predict the long term behaviour of adhesively bonded steel joints aged in sea water. First, diffusion kinetics and the mechanisms governing the degradation of mechanical properties of an epoxy adhesive are described. These two sets of data were used in a coupled finite element (FE) analysis to determine the stress state in double lap shear (DLS) specimens before and after aging. However, subsequent tests on DLS specimens indicated an adhesive and not cohesive failure mode, so this approach could not be used to predict failure in the present case without introducing an interfacial damage parameter. A second approach was therefore employed, in which modified Arcan samples were designed in order to identify directly how the failure envelope changed with aging. Tests were performed on these modified Arcan specimens under shear, tensile/shear and tensile loads before and after aging. The results from these tests have enabled a tension–shear failure envelope to be constructed, which may be used to predict failure in joints with more complex stress states. The application of a coupled diffusion–mechanical property approach is illustrated for the Arcan specimen loaded in tension, and its application to the prediction of failure behaviour after aging is discussed.

A General Methodology to Predict Fatigue Life in Lead-Free Solder Alloy Interconnects

The ubiquitous eutectic tin-lead (Sn–Pb) solder alloys are soon to be replaced with lead-free alternatives. In light of this transition, new computational tools for predicting the fatigue life of lead-free solders are required. A fatigue life prediction methodology was developed, based on stress-strain, creep, and isothermal fatigue data; the latter generated using a double lap-shear (DLS) test assembly. The proposed fatigue life prediction methodology builds on current practices in fatigue prediction for solder alloys, particularly the concepts of unpartitioned energy methods in finite element analysis (FEA) and continuum damage mechanics. As such, the current state of these fields is briefly discussed. Next, the global and local FEA simulations of the DLS test assembly are detailed. A correlation is then made between the empirical data and the FEA simulations. A general fatigue life prediction methodology is next described in detail. Finally, this methodology is tested and verified against the empirical data.

Experimental and numerical investigations into the effect of an interference fit on the fatigue life of double shear lap joints

In this research the effect of bolt interference fit on the fatigue life of lap joints in double shear was investigated by conducting experimental fatigue tests and also analytically by FE simulation. In the experimental part, fatigue tests were carried out on specimens made from aluminium alloy 2024-T3 plates joined together as double lap joints and secured using bolts having fits ranging from zero clearance to different levels of interference. The results demonstrate how the failure is affected using different levels of interference fit. In the numerical study, 3-D FE models were used to simulate the different pin in hole fits considered and the results have been used to help explain the trends which were observed in the experimentally obtained S– N curve behaviour.

Numerical simulation of delamination in laminated composite components – A combination of a strength criterion and fracture mechanics

An approach for the numerical treatment of delamination in laminated composite components is presented. A first ply failure criterion is employed to predict delamination initiation, while delamination propagation is analyzed using linear elastic fracture mechanics. The combination of initiation and propagation criteria yields a conservative estimation of the load earring capacity of a structure. Furthermore, the growth stability, the sensitivity of the results with respect to a change in the interface properties, and the non-linear structural response caused by the delamination growth process are determined. Two structures are investigated, which show the capability of the proposed approach, a curved laminate and a double lap shear test specimen.

Effect of Elevated Temperature on Bond Behaviour of High Modulus CFRP/Steel Double-Strap Joints

This paper investigates and provides experimental evidence of the bond characteristics between carbon fibre reinforced polymer (CFRP) and steel plates under elevated temperature exposures. A series of tensile tests was carried out on CFRP/steel plates specimens joined together in double-lap shear joints and subjected to a range of environmental temperatures between 20 °C up to 60 °C, which would be usually encountered in civil infrastructure applications. High modulus (640 GPa) unidirectional carbon fibre plies were used in wet lay-up fabrication method to strengthen the composite matrix. Three different epoxy resins were used for the fabrication of the CFRP/steel specimens. The objective of the current experimental work is to determine the ultimate strength, failure patterns, elongation development, and lap-shear stress and slip variation under those exposures. This will help in enhancing the competency of using CFRP in retrofitting steel structures at high-temperature environments, usually experienced in civil construction applications.

Prediction of debonding strength of tensile steel/CFRP joints using fracture mechanics and stress based criteria

In this paper, the debonding strength of axially loaded double shear lap specimens between steel plates and carbon fibre reinforced plastic plates is investigated from the analytical, numerical and experimental point of view. Two steel plates were joined together by two carbon fibre reinforced plastic (CFRP) plates and epoxy adhesive in order to realize double shear lap specimens of different length. Failure of the steel–adhesive interface was identified as the dominant failure mode and fracture mechanics and stress based approach are presented in order to estimate the relevant failure load. A good agreement between the analytical–numerical results and experimental data is achieved.

Numerical prediction of load–displacement behaviors of adhesively bonded joints at different extension rates and temperatures

The present work focuses on simulation of nonlinear mechanical behaviors of adhesively bonded DLS (double lap shear) joints for variable extension rates and temperatures using the implicit ABAQUS solver. Load-displacement curves of DLS joints at nine combinations of extension rates and environmental temperatures are initially obtained by conducting tensile tests in a UTM. The joint specimens are made from dual phase (DP) steel coupons bonded with a rubber-toughened adhesive. It is shown that the shell-solid model of a DLS joint, in which substrates are modeled with shell elements and adhesive with solid elements, can effectively predict the mechanical behavior of the joint. Exponent Drucker-Prager or Von Mises yield criterion together with nonlinear isotropic hardening is used for the simulation of DLS joint tests. It has been found that at a low temperature (-20 degrees C), both Von Mises and exponent Drucker-Prager criteria give close prediction of experimental load-extension curves. However. at a high temperature (82 degrees C), Von Mises condition tends to yield a perceptibly softer joint behavior, while the corresponding response obtained using exponent Drucker-Prager criterion is much closer to the experimental load-displacement curve.

Strength of resin-coated-adhesive-bonded double lap-shear pultrusion joints at ambient temperature

The inherited adhesion limitation of polyester and vinyl ester resin-based pultruded GFRP makes pultrusions difficult to bond, especially when a thixotropic adhesive is used. While such an adhesive is necessary for gap filling, it has a limited wettability. Therefore, coating the adherend with low-viscosity epoxy resin, prior to bonding, improves wetting and hence increases joint strength. The paper describes the experimental methodology to achieve this, using double lap-shear (DLS) joints with various materials combinations. A significant strength improvement was reached as a result of coating the inner adherend in conjunction with using a “high adhesion” outer adherend. To further understand the effect of coating, numerical stress analysis was undertaken, including preliminary micro-models representing the composite/adhesive interface as well as overall DLS models.