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NASA NTRS1974

Advances in the analysis and design of adhesive-bonded joints in composite aerospace structures

Several aspects of adhesive-bonded joint analysis and design are presented from the reference of size of structure or load intensity. This integrates the individual characterizations of double-lap, single-lap, stepped-lap, tapered-lap and scarf joints. The paper includes an overview of bonded joint selection from the standpoints of design, fabrication, and processing, each bearing in mind the influence of such considerations on the strength of the joint. A case study is presented of the optimization of a specific relatively thick titanium-to-graphite epoxy stepped-lap joint, using the digital computer analysis program A4EG. The factors accounted for are adhesive plasticity, adherend stiffness imbalance, adherend thermal mismatch, and change of material properties within the range of temperature environment and with load direction. The strength increases obtainable by refining the initial design are demonstrated.

Hart-Smith, L. J.↗

NASA NTRS1975

The effect of bending on the stresses in adhesive joints

The problem of stress distribution in adhesive joints where two orthotropic plates are bonded through a flexible adhesive layer is analyzed. It is shown that the effect of bending of the adherends on the stresses in the adhesive layer is very significant. The transverse shear deformations of the adherends appear to have little influence on the adhesive layer stresses. The maximum transverse normal stress in the adhesive is shown to be larger than the maximum longitudinal shear stress. The method of solution is applied to several examples of specific joint geometries and material combinations, and is proven to be applicable to other related problems.

Yuceoglu, U.↗

NASA NTRS1975

Stress analysis of adhesive bonded stiffener plates and double joints

The general problem of adhesive bonded stiffener plates and double joints of dissimilar orthotropic adherends with transverse shear deformations are analyzed. Adhesive layers are assumed to be of an isotropic, elastic and relatively flexible material. It is shown that the stress distributions in the adhesive layers are very much dependent on the bending deformations in adherends. Also, it is found that, in the adhesive layer, maximum transverse normal stress is, in many cases, larger than the longitudinal shear stress and that both occur at the edge of the joint. The general method of solution developed is applied to several practical examples.

Yuceoglu, U.↗

NASA NTRS1976

Cyclic debonding of unidirectional composite bonded to aluminum sheet for constant-amplitude loading

Cyclic debonding rates were measured during constant-amplitude loading of specimens made of graphite/epoxy bonded to aluminum and S-glass/epoxy bonded to aluminum. Both room-temperature and elevated-temperature curing adhesives were used. Debonding was monitored with a photoelastic coating technique. The debonding rates were compared with three expressions for strain-energy release rate calculated in terms of the maximum stress, stress range, or a combination of the two. The debonding rates were influenced by both adherent thickness and the cyclic stress ratio. For a given value of maximum stress, lower stress ratios and thicker specimens produced faster debonding. Microscopic examination of the debonded surfaces showed different failure mechanisms both for identical adherends bonded with different adhesive and, indeed, even for different adherends bonded with identical adhesives. The expressions for strain-energy release rate correlated the data for different specimen thicknesses and stress ratios quite well for each material system, but the form of the best correlating expression varied among material systems. Empirical correlating expressions applicable to one material system may not be appropriate for another system.

Roderick, G. L.↗

NASA NTRS1977

A fundamental approach to adhesion: Synthesis, surface analysis, thermodynamics and mechanics

The effects of composites as adherends was studied. Several other variables were studied by fractography: aluminum powder adhesive filler, fiber glass cloth scrim or adhesive carrier, new adhesives PPQ-413 and LARC-13, and strength-test temperature. When the new results were juxtaposed with previous work, it appeared that complex interactions between adhesive, adherend, bonding, and testing conditions govern the observed strength and fracture-surface features. The design parameters likely to have a significant effect upon strength-test results are listed.

Dwight, D. W.↗

NASA NTRS1979

Polyimide adhesive bonding

Adhesive systems which could be used to bond composite-to-composite, composite-to-titanium, and honeycomb sandwich structures with operational capability at 589K for a minimum of 125 hours were evaluated. Evaluations were based on mechanical property tests such as lap shear and flatwise tensile and on processability. Quasi-isotropic Celion 6000/PMR-15 composite adherend was used to construct lap shear and flatwise tensile specimens. Hexcel's HRH-327-3/16-6.0 glass polyimide honeycomb core was also utilized in the flatwise tensile specimens. Numerous processing variations were also studied that led to selected cure cycles for each adhesive. Shear specimens having either 12 mm or 75 mm overlaps were used to determine the effect of bond size on processability and lap shear properties. The data indicate that processing of FM-34, FM-34B-18, LARC-13 and NRO56X can be achieved using a cure compatible with the composite adherend. No significant differences in mechanical properties were observed among the three adhesive systems and all three are suitable candidates for 589K/125 hour service.

Progar, D.↗

NASA NTRS1979

NR-150 adhesive development

A polyimide precursor adhesive solution, code-named NR-056X, was developed. It reproducibly gives low void, high strength bond lines at both room temperature and 589K (600 F) using either titanium or graphite/polyimide composite adherends having 12.7 mm (1/2 in.) overlaps. Lap shear samples prepared using this adhesive and composite adherends based on graphite/NR-150B2 were shown to have a high degree of resistance to such adverse environments as air at 589K (600 F), high humidity, methyl ethyl ketone and jet fuel. Bond line toughness was illustrated by the complete resistance to cracking in the wedge-crack propagation test. The available evidence indicates that wide area composite to composite or composite to metal bonding should be feasible.

Blatz, P. S.↗

NASA NTRS1980

Viscoelastic analysis of adhesively bonded joints

An adhesively bonded lap joint is analyzed by assuming that the adherends are elastic and the adhesive is linearly viscoelastic. After formulating the general problem a specific example for two identical adherends bonded through a three parameter viscoelastic solid adhesive is considered. The standard Laplace transform technique is used to solve the problem. The stress distribution in the adhesive layer is calculated for three different external loads, namely, membrane loading, bending, and transverse shear loading. The results indicate that the peak value of the normal stress in the adhesive is not only consistently higher than the corresponding shear stress but also decays slower.

Delale, F.↗

NASA NTRS1980

Stress analysis of bonded plates and joints

The paper presents a general numerical method of solution to the transverse normal stress and longitudinal shear stress distributions in the adhesive layers of bonded stiffener plates, double lap joints, and strap joints, all of dissimilar orthotropic adherends. The bending deformations and the transverse shear deformations are included in the analytical model. The present influence of bending deformations of adherends on both the normal and shear stresses in adhesive layers is discussed in detail for practical cases.

Yuceoglu, U.↗

NASA NTRS1981

Viscoelastic analysis of adhesively bonded joints

In this paper an adhesively bonded lap joint is analyzed by assuming that the adherends are elastic and the adhesive is linearly viscoelastic. After formulating the general problem a specific example for two identical adherends bonded through a three parameter viscoelastic solid adhesive is considered. The standard Laplace transform technique is used to solve the problem. The stress distribution in the adhesive layer is calculated for three different external loads namely, membrane loading, bending, and transverse shear loading. The results indicate that the peak value of the normal stress in the adhesive is not only consistently higher than the corresponding shear stress but also decays slower.

Delale, F.↗

NASA NTRS1981

Stresses in adhesively bonded joints - A closed-form solution

The general plane strain problem of adhesively bonded structures consisting of two different, orthotropic adherends is considered, under the assumption that adherend thicknesses are constant and small in relation to the lateral dimensions of the bonded region, so that they may be treated as plates. The problem is reduced to a system of differential equations for the adhesive stresses which is solved in closed form, with a single lap joint and a stiffened plate under various loading conditions being considered as examples. It is found that the plate theory used in the analysis not only predicts the correct trend for adhesive stresses but gives surprisingly accurate results, the solution being obtained by assuming linear stress-strain relations for the adhesive.

Delale, F.↗

NASA NTRS1982

A critical study of the role of the surface oxide layer in titanium bonding

The molecular understanding of the role which the surface oxide layer of the adherend plays in titanium bonding is studied. The effects of Ti6-4 adherends pretreatment, bonding conditions, and thermal aging of the lap shear specimens were studied. The use of the SEM/EDAX and ESCA techniques to study surface morphology and surface composition was emphasized. In addition, contact angles and both infrared and visible reflection spectroscopy were used in ancillary studies.

Dias, S.↗

NASA NTRS1982

Geometrically nonlinear analysis of adhesively bonded joints

A geometrically nonlinear finite element analysis of cohesive failure in typical joints is presented. Cracked-lap-shear joints were chosen for analysis. Results obtained from linear and nonlinear analysis show that nonlinear effects, due to large rotations, significantly affect the calculated mode 1, crack opening, and mode 2, inplane shear, strain-energy-release rates. The ratio of the mode 1 to mode 2 strain-energy-relase rates (G1/G2) was found to be strongly affected by he adhesive modulus and the adherend thickness. The ratios between 0.2 and 0.8 can be obtained by varying adherend thickness and using either a single or double cracked-lap-shear specimen configuration. Debond growth rate data, together with the analysis, indicate that mode 1 strain-energy-release rate governs debond growth. Results from the present analysis agree well with experimentally measured joint opening displacements.

Dattaguru, B.↗

NASA NTRS1983

Optimization of bonded joints

A procedure for minimizing the elastic shear stress concentration in adhesive lap joints is presented. The proposed method is based upon tapering the adherends to achieve smooth stiffness transitions and uniform shear stresses. Both single and double lap splices are considered, but numerical examples are restricted to the case of double lap joints. Nonisotropic materials and nonoptimum design limitations, such as minimum and maximum thickness adherends, load-line eccentricity, and peel stresses are treated, and typical results are presented.

Ojalvo, I. U.↗

NASA NTRS1983

Effect of stitching on the strength of bonded composite single lap joints

An experimental investigation has been conducted to determine the effect of stitching on the static and fatigue failure load of bonded composite single lap joints. The variables considered in the static tests included adherend thickness, overlap length, stitch spacing, and number of rows of stitches. A limited fatigue program was conducted for one configuration to compare the fatigue life of stitched and unstitched joints. Up to a 38 percent improvement in static failure load and an order of magnitude increase in fatigue life compared with unstiffened results are obtained by a single row of stitches near the end of the overlap. Additional rows of stitching or different stitch spacing has little effect on static joint failure load. Thicker adherends and larger overlap length result in larger improvements in static failure load with stitching. Further research is needed to refine the stitching process in order to obtain the maximum improvements in joint failure load.

Sawyer, J. W.↗

NASA NTRS1984

Rapid adhesive bonding concepts

Adhesive bonding in the aerospace industry typically utilizes autoclaves or presses which have considerable thermal mass. As a consequence, the rates of heatup and cooldown of the bonded parts are limited and the total time and cost of the bonding process is often relatively high. Many of the adhesives themselves do not inherently require long processing times. Bonding could be performed rapidly if the heat was concentrated in the bond lines or at least in the adherends. Rapid adhesive bonding concepts were developed to utilize induction heating techniques to provide heat directly to the bond line and/or adherends without heating the entire structure, supports, and fixtures of a bonding assembly. Bonding times for specimens are cut by a factor of 10 to 100 compared to standard press bonding. The development of rapid adhesive bonding for lap shear specimens (per ASTM D1003 and D3163), for aerospace panel bonding, and for field repair needs of metallic and advanced fiber reinforced polymeric matrix composite structures are reviewed.

Stein, B. A.↗

NASA NTRS1984

Geometrically nonlinear analysis of adhesively bonded joints

A geometrically nonlinear finite element analysis of cohesive failure in typical joints is presented. Cracked-lap-shear joints were chosen for analysis. Results obtained from linear and nonlinear analysis show that nonlinear effects, due to large rotations, significantly affect the calculated mode 1, crack opening, and mode 2, inplane shear, strain-energy-release rates. The ratio of the mode 1 to mode 2 strain-energy-release rates (G1/G2) was found to be strongly affected by the adhesive modulus and the adherend thickness. The ratios between 0.2 and 0.8 can be obtained by varying adherend thickness and using either a single or double cracked-lap-shear specimen configuration. Debond growth rate data, together with the analysis, indicate that mode 1 strain-energy-release rate governs debond growth. Results from the present analysis agree well with experimentally measured joint opening displacements. Previously announced in STAR as N83-13497

Dattaguru, B.↗

NASA NTRS1985

Elasticity Solution of an Adhesively Bonded Cover Plate of Various Geometries

The plane strain of adhesively bonded structures consisting of two different isotropic adherends is considered. By expressing the x-y components of the displacements in terms of Fourier integrals and using the corresponding boundary and continuity conditions, the integral equations for the general problem are obtained and solved numerically by applying Gauss-Chebyshev integration scheme. The shear and the normal stresses in the adhesive are calculated for various geometries and material properties for a stiffened plate under uniaxial tension. Numerical results involving the stress intensity factors and the strain energy release rate are presented. The closed-form expressions for the Fredholm kernels are provided to obtain the solution for an arbitrary geometry and material properties. For the general geometry, the contribution of the normal stress is quite significant, while for symmetric geometries, the shear stress is dominant, the normal stress vanishes if the adherends are of the same material and the same thickness.

Aksel, G. N.↗