Large scale structures such as those in aerospace flight vehicles are made in parts and assembled. Joints are inevitable in these systems and they are potential threats to the structural integrity of the flight vehicles. Fastener and bonded joints are the most commonly used methods of joining in these structures. Among these, adhesive bonding has become more popular with the advent of composite structures, due to the presence of less number of points of stress concentration and the resulting benefit for static strength and fatigue life. In modern aircraft in which maximum percentage of composite materials are being employed due to several benefits, designers are contemplating to replace discrete joints with adhesively bonded joints wherever possible. A detailed literature survey shows that the field of adhesively bonded joints has been extensively studied in the past. Initial publications appeared in late 1950’s and early 1960's, but many of the initial attempts were based on one dimensional (1-D) approximation of the adherents due to lack of computing power. With the current day emphasis on safety and damage tolerance, there is a definite need to study these joints with 2-D and 3-D idealization. In spite of valuable contributions in the literature from several researchers in past 4-5 decades, one finds that there are gaps to be filled, in particular, with reference to static strength prediction and de-bond growth to failure under fatigue loading. This thesis is intended as a modest contribution in this direction covering the methods of strength prediction and also correlations between de-bond growth and fracture parameters. Most commonly used bonded joints are single lap joints. The primary issue in their analysis is the geometric nonlinearity resulting in large deformations due to eccentricity of load path between the adherents. Further, adhesives have very low yield strength and plastic deformation in thin adhesives could affect the mechanics of load transfer. The current work is initiated by carrying out geometric and material nonlinear analysis of adhesively bonded single lap joints between metal-metal (aluminum-aluminum) adherents using standard NASTRAN finite element software. Modified Newton-Raphson iterative technique has been used to economize the computer time and also achieve fast convergence. A convergence study has been conducted to determine the order of mesh size required. Preliminary results are obtained on configurations analysed by earlier workers and the current results are compared with their results. Later, extensive experimental and numerical studies have been taken up on the numerical strength prediction of these joints correlating them to the experimental values. Cohesive failure along the centre line of the adhesive is assumed under both static and fatigue loading. The bonded joints are studied with both 2-D plane stress and plane strain nonlinear FE analysis. The issue in this type of analysis is the presence of theoretical elastic singularity at the ends of the lap length. The normally used maximum stress criterion can not be used in such circumstances. There were attempts in the past to use point stress or average stress criteria for this purpose. In point stress criterion the shear stress (or von-Mises stress) is picked at a characteristic distance away from the ends of the lap length and compared with the corresponding strength value to predict failure. In the average stress criterion the stresses are averaged over a characteristic distance from the ends of lap length and this is compared with the corresponding strength to predict failure. Determination of the characteristic distance in both the cases needs extensive experimental results on static strength of joints. The static strength data is to be correlated with numerical results to determine the characteristic distance in various specimens. In the current thesis a series of specimens with aluminum-aluminum, aluminum-CFRP composite and CFRP-CFRP composite adherents were tested to determine the static strength. In all the specimens the adhesive used was Redux 319 A. These experimental strength data was used to determine characteristic distance using point stress criterion. The consistency of estimates of the characteristic distances in all the specimens shows that the approach is capable of predicting the static strength. The above approaches are capable of predicting the strength of joints with linear material and nonlinear geometric analysis. But when the adhesive yield strength is low, a novel approach is required to predict the static strength. Numerical analysis is conducted using a combined material and geometric nonlinear analysis in NASTRAN software. The plastic zone size from the ends of the lap length is determined at different load levels. Combining the numerical results with experimental failure load data, a failure criterion based on plastic zone size (PZS) is proposed in this thesis and validated. It has been observed that the validation is with limited testing carried out and further experimental programs are required to complete the validation. To the best of the knowledge of the author PZS criterion is used for the first time for failure prediction of bonded joints. The structural integrity of the joints also requires a study of de-bond growth and damage tolerance assurances in the presence of de-bond type of defects. The first step in this direction is to estimate the fracture parameters at the tips of de-bond in the adhesive of lap joints between various adherents. Modified virtual crack closure integral (MVCCI) technique has been developed in the past for estimating Strain Energy Release Rates (SERR) in several crack problems. Large contributions for developing this technique have come from the group where the author has worked. This technique is simple and has the ability to estimate individual SERR components GI and GII in cases of mixed mode fracture. It is seen clearly that the de-bond growth in bonded joint is one of mixed mode. The mode-II component is because of shear stresses transferring the load across the adherents and mode-I component is due to peel stresses developed during the deformation. The mode I SERR component is primarily responsible for de-bond growth and the effect of mode II component on de-bond growth is insignificant. The mesh details for accurately estimating the SERR components are evaluated and those meshes are used to estimate these values for the cases of aluminum-aluminum, aluminum-CFRP composite and composite-composite joints. Obviously, when the adherents are dissimilar, mode I SERR components are the highest and assist faster de-bond growth. Painstaking fatigue de-bond growth experiments were conducted and de-bond growth rate with number of cycles of fatigue loading was determined. MVCCI method is used to estimate SERR components at maximum load and zero load in the fatigue cycle, to determine the SERR range in the fatigue cycle. Since the stress ratio, R of the loading cycle is -1, the minimum load for estimating SERR components is taken as zero. From the experimental data and numerical estimates, a Paris type of equation was developed for the de-bond growth. The thesis concludes with a summary of the achievements in the current work with respect to the structural integrity of adhesively bonded joints and also with suggestions for future work.

A simplified model is proposed to investigate the stress fields and the strain energy release rate (SERR) associated with cracks in bonded joints in wind turbine blades. The proposed two-dimensional model consists of nonparallel upper and lower shells with adhesive between the shells at the tapered end. Nonlinear finite element analysis (FEA) is performed in a systematic parametric study of material and geo- metric properties. Two failure modes and their locations are predicted at different combinations of parameters: yielding at the outside end of the adhesive and interface cracking at the inside end of the bondline. Effect of the shell curvature on the stress fields is also considered. Based on the classic beam theory and the beam-on-elastic-foundation (BOEF) assumption, stress and displacement fields of the adhesively-bonded joint were determined by a new theoretical model to support the results from the numerical computation. The failure analysis is continued by studying the effects of manufacturing defects in the adhesive bond. Single and multiple voids are embedded to simulate air bubble trapped in the interface. The numerical and analytical studies are conducted to investigate SERR associated with the voids and results are provided to illustrate the effects of void position and void size.

Simulations using the Finite Element Method (FEM) play an increasingly important role in the design process of joints and fasteners in the aerospace industry. In order to utilize the potential of such adhesive bonding, there is an increasing need for effective and accurate computational methods. The geometry and the nature of an adhesive joint are, however, not so simple to describe effectively using standard FEM-codes. To overcome this difficulty, special FEM-elements can be developed that provide a material surface treatment of the adhesive and the joined parts. In order to create a model that reflects the above features, one may introduce proper scalings on the geometry and on the material properties in terms of a perturbation parameter. Within the framework of three-dimensional elasticity, together with an asymptotic expansion method, a material surface model is obtained through a systematic procedure. In such a derivation, no a priori assumptions for the displacements or stress fields are needed. The final result is a variational equation posed over a single reference surface which forms the basis of a structural element for the compound joint. Through the usage of continuum damage mechanics and the framework of a generalized standard material, the linear elastic model is extended to include an elastic-plastic material model with damage for the adhesive. The model is FE-discretized and an important implication is that the (quasi-static) propagation of the local failure zone in the adhesive layer can be simulated. The failure load is obtained as a computational result and consequently no postulated failure criterion is needed. The derived FE-method opens up the possibility to efficiently model and analyze the mechanical behavior of large bonded structures. / At the time the thesis was defended paper I. was in fact two manuscripts, which later were combined to give the published article.

Le collage structural se présente comme une alternative intéressante aux méthodes classiques d'assemblages par ajout d’éléments mécaniques pour alléger les structures aéronautiques. Cependant, l'utilisation de cette méthode soulève de nombreuses questions en termes de conception, caractérisation ou modélisation. Ce travail, à fort caractère expérimental, visent deux grands objectifs : (i) sélectionner les moyens d'instrumentation les plus adaptés pour la caractérisation du comportement jusqu'à rupture des assemblages collés et (ii) prédire le comportement des assemblages collés à partir d'une caractérisation et d'une modélisation complète sous chargements quasi-statiques bi-axiaux, en utilisant un type d’essai simple et industrialisable. Dans un premier temps, pour atteindre ces objectifs, un nouvel essai appelé Scarf modifié a été proposé, afin de caractériser le comportement mécanique du joint de colle, en minimisant les effets de bord par la présence de becs. La deuxième partie de la thèse porte sur le développement d'une stratégie de caractérisation simplifiée du comportement de joint de colle, sous certaines hypothèses (états de contraintes/déformations, continuité du champ de contraintes). Cette stratégie a permis d'obtenir le comportement intrinsèque de l’adhésif sous la forme de courbes contraintes/déformations. La dernière partie abordée dans ces travaux, s'intéresse quant à elle à l'identification et la sélection des moyens de métrologie les plus appropriés, pour accompagner la caractérisation expérimentale. / Today, structural bonding presents an interesting alternative to conventional methods of assembly, in order to reduce the weight within aeronautical structures. However, the use of this method raises many questions in terms of design, characterization or modeling. This work presents a robust experimental work, aiming two main objectives: (i) select the most suitable instrumentation for the characterization of the behavior of bonded joints up to failure and (ii) predict the behavior of bonded joints from complete characterization and modeling under quasi-static bi-axial loading, using a simple test, directly integrated to industry. In a first stage, to achieve this goal, modified Scarf test has been proposed to characterize the mechanical behavior of adhesive joints. This type of specimen allows applying multiaxial loadings without having high-stress concentrations near the edges. The second part of the thesis deals with the development of a strategy for simplifying the characterization of a bonded joint using some hypotheses (stress/strain states). This strategy allows obtaining the intrinsic behavior of the adhesive in the form of the stress/strain curves. The last part of this work deals with the identification and selection of the most appropriate instrumentation systems in the experimental characterization.

Adhesively bonded joints have been investigated for several decades. In most analytical studies, the Bernoulli-Euler beam theory is employed to describe the behaviour of adherends. In the current work, three analytical models are developed for adhesively bonded joints using the Timoshenko beam theory for elastic material and a Bernoulli-Euler beam model for viscoelastic materials. One model is for the peeling test of an adhesively bonded joint, which is described using a Timoshenko beam on an elastic foundation. The adherend is considered as a Timoshenko beam, while the adhesive is taken to be a linearly elastic foundation. Three cases are considered: (1) only the normal stress is acting (mode I); (2) only the transverse shear stress is present (mode II); and (3) the normal and shear stresses co-exist (mode III) in the adhesive. The governing equations are derived in terms of the displacement and rotational angle of the adherend in each case. Analytical solutions are obtained for the displacements, rotational angle, and stresses. Numerical results are presented to show the trends of the displacements and rotational angle changing with geometrical and loading conditions. In the second model, the peeling test of an adhesively bonded joint is represented using a viscoelastic Bernoulli-Euler beam on an elastic foundation. The adherend is considered as a viscoelastic Bernoulli-Euler beam, while the adhesive is taken to be a linearly elastic foundation. Two cases under different stress history are considered: (1) only the normal stress is acting (mode I); and (2) only the transverse shear stress is present (mode II). The governing equations are derived in terms of the displacements. Analytical solutions are obtained for the displacements. The numerical results show that the deflection increases as time and temperature increase. The third model is developed using a symmetric composite adhesively bonded joint. The constitutive and kinematic relations of the adherends are derived based on the Timoshenko beam theory, and the governing equations are obtained for the normal and shear stresses in the adhesive layer. The numerical results are presented to reveal the normal and shear stresses in the adhesive.

The effects of high loading rates (HLR), and nano reinforcement on the mechanical response of adhesively-bonded SLJs with composite adherends, subjected to different loading (strain) rates are systematically investigated. The results are then compared to those of neat thermoset resin and thermo-plastic adhesive. More specifically, nano-reinforced and neat resin bonded joints mating carbon/epoxy and glass/epoxy adherends were subjected to tensile loadings under 1.5 and 3 mm/min and tensile impacts at a loading rate of 2.04E+5 mm/min. In some cases, additional tests were conducted under 15, 150, and 1500 mm/min to obtain additional properties gained using the nano-reinforcements for use in the further numerical investigations. The HLR tests were conducted, using a modified instrumented pendulum equipped with a specially designed impact load transfer apparatus. The dispersion of nanoparticles was facilitated using a mechanical stirrer and a three-roll mill machine. The failure mechanisms were studied with a scanning electron microscope.

Using experimental data obtained from standard fracture test configurations, theoretical and numerical tools are developed to mathematically describe non-self-similar progression of cracks without specifying an initial crack. A cohesive-decohesive zone model, similar to the cohesive zone model known in the fracture mechanics literature as the Dugdale-Barenblatt model, is adopted to represent the degradation of the material ahead of the crack tip. This model unifies strength-based crack initiation and fracture-mechanics-based crack progression. The cohesive-decohesive zone model is implemented with an interfacial surface material that consists of an upper and a lower surface that are connected by a continuous distribution of normal and tangential nonlinear elastic springs that act to resist either Mode I opening, Mode II sliding, Mode III sliding, or a mixed mode. The initiation of fracture is determined by the interfacial strength and the progression of the crack is determined by the critical energy release rate. The adhesive is idealized with an interfacial surface material to predict interfacial fracture. The interfacial surface material is positioned within the bulk material to predict discrete cohesive cracks. The interfacial surface material is implemented through an interface element, which is incorporated in ABAQUS using the user defined element (UEL) option. A procedure is established to formulate a rate dependent model based on experiments carried out on compact tension test specimens. The rate dependent model is incorporated into the interface element approach to capture the unstable crack growth observed in experiments under quasi-static loading conditions. The compact tension test gives the variation of the fracture toughness with the rate of loading, this information is processed and a relationship between the fracture toughness and the rate of the opening displacement is established. The cohesive-decohesive zone model is implemented through a material model to be used in an explicit code (LS-DYNA). Dynamic simulations of the standard test configurations for Mode I (Double Cantilever Beam) and Mode II (End Load Split) are carried out using the explicit code. Verification of these coupon tests leads to the crash analysis of realistic structures like the square composite tube. Analyses of bonded and unbonded square tubes are presented. These tubes shows a very uncharacteristic failure mode: the composite material disintegrates on impact, and this has been captured in the analysis. Disadvantages of the interface element approach are well documented in the literature. An alternative method, known as the Extended Finite Element Method (XFEM), is implemented here through an eight-noded quadrilateral plane strain element. The method, based on the partition-of-unity, is used to study simple test configuration like the three-point bend problem and a double cantilever beam. Functionally graded materials are also simulated and the results are compared to the experimental results available in the literature. / Ph. D.

PR-2930 was developed by PPG Industries, Inc. to meet the challenging performance requirements of MIL-PRF-32662 Group-I-classified adhesives. PR-2930 is a high-strength, high-toughness, epoxy-based adhesive intended for automotive and aerospace applications. As PR-2930 functions as a structural adhesive, quantification of its mechanical properties and limit-states is a necessary task for designing joints bonded with the adhesive. The combination of both strength and ductility results in material non-linearities, making experimental characterization and numerical analyses more challenging. This work explores the quantification of fracture energy for PR-2930 bonded joints. Fracture can occur in one of three different modes, or in some combination. Many practical adhesive joints fail in the mixed-mode region involving both opening (mode I) and shearing (mode II) displacements. Mode I fracture was evaluated with double cantilever beam (DCB) tests, mode II fracture was characterized by end-notched flexure (ENF) tests, and varying degrees of mixed mode I/II fracture were assessed through single leg bend (SLB), single-lap joint (SLJ), and asymmetric DCB and SLB tests. Test specimens were fabricated by bonding Al 2024-T3 adherends, ranging from 1.6 mm to 25.4 mm thick, with a 0.25 mm thick PR-2930 adhesive layer. Digital image correlation (DIC) was used to experimentally measure local displacements and surface strains on the adherends. Standard data-reduction methods often used to determine fracture energies of bonded joint specimens were used to numerically analyze test results. These methods included the Corrected Beam Theory (CBT), the Compliance-Based Beam Method (CBBM), and the Paris and Paris J-Integral approach. Linear elastic fracture mechanics (LEFM) conditions must be valid to correctly apply these methods, however plastic deformations were observed in some adherends. Drawbacks of these approaches and their validity for analyzing PR-2930 joints were discussed. To account for non-linearities, more advanced numerical analysis was performed using finite element analysis (FEA) with cohesive zone models (CZMs) to model the adhesive layer. CZM parameters such as fracture energies and traction separation law (TSL) shapes were determined from experimental data and published literature. Results from CZMs were compared to experimental load, displacement, and strain data. Recommended TSLs for mode I and mode II fracture were formed in this work as well as a mixed-mode relationship using a Benzeggagh-Kenane damage evolution law. More ideal analytical methods were suggested to simplify analysis of joints using the same or similar material compositions. / M.S. / Structural adhesives are used to safely transmit loads in our furniture, automobiles, aircraft, and buildings. PR-2930 is a newly developed epoxy that exhibits top-of-the-line strength and ductility. To safely design joints utilizing PR-2930, the bonding material and its limit states must be defined. The most pertinent mechanical limit state for adhesively bonded joints is its resistance to fracture, also known as fracture toughness. Fracture often occurs due to a combination of opening (mode I) or shearing (mode II) displacements. In this work, standard and novel advanced fracture characterization techniques are employed and subsequently compared. Adhesive joints using a 0.25 mm layer thickness are bonded to Al 2024-T3 adherends varying from 1.6 mm to 25.4 mm of thickness and tested in quasistatic conditions. Mathematical models of mode I, mode II, and combined mode I/II stress displacement responses (AKA a traction-separation laws) of PR-2930 are developed and compared with experimental data. Future experimental and numerical methods for fracture analysis of structural adhesives are discussed.

Joints in structures always cause strength reduction. The percentage of strength reduction depends upon the selection of several factors such as: type of joint (i.e. adhesive or mechanical), technique of joint (i.e. lap joint, butt joint etc.), geometry of joint, mode of load application etc. Here in this research, the strength of adhesively bonded butt joints with several geometries, later referred as joint angles, is investigated under uniaxial tension loading. Adhesively bonded simple butt joints, where joints are placed perpendicular to the loading direction are in common practice mainly because of ease in manufacturing process. But when the joint is fabricated with an angle respective to the loading direction, the geometry of the joint itself affects the strength of the joint significantly. Without going too deep into other factors that affects the joint strength such as manufacturing techniques, manufacturing defects, material behavior etc. only the geometry of the joint is considered and it is evaluated whether it is worth to change the joint geometry or not. The significant issue in adhesive joint technology is the prediction of joint strength. However, an approach similar to plastic yield criterion later referred as elastic limit offset method (attempted for 0.025% offset) is considered to estimate the linear elastic limit. Since RUAG Space AB (the industry for which this project is performed) is only interested in the linear elastic regime of the stress-strain curve, therefore the elastic limit offset method is considered to be the suitable one. The present work is concerned with the study of adhesively bonded angled butt joint vs. strength behavior. The strength of adhesively bonded butt joints is examined for several butt joint angles under uniaxial tensile loading. The employed butt joint angles are: 0°, 30°, 45°, 60° and 75°. The main objective of the current investigation is to find the joint angle that has the highest strength or the highest capability of load transfer. In addition to the above, the influence of the joint on the stress field, joint strength and type of failure is also evaluated using DSP (Digital Speckle Photography) technique and simulated using well known finite element tool, ABAQUS. It is observed that specific strength of the joint is greatly influenced with joint angle. The 45° joint showed the highest elasticity and failed like ductile behavior whereas 75° joint showed the lowest elasticity and failure was purely brittle. Moreover, post-failure inspection of fractured surfaces showed cohesive failure (failure within adhesive layers) for 0°, 30°, 45° and 60°whereas 75° showed composite or adherend failure. The simulation is performed for each joint angle. However to validate the model only 45° and 75° joints results are compared with experimental results and plotted in the report. The simulation results of these angles showed good agreement with the experimental ones. Moreover, the stress fields for each joint angle are captured (from ABAQUS), showing that all joints are susceptible to inter-laminar shear. Besides, the relative slip between the top and middle adherends is also calculated, the results show that, the 45° joint has higher tendency of relative slip than others.

This study focuses on factors that affect the structural integrity of wood-based composites. Wood-based composites exposed to fire may decompose due to the elevated temperatures, resulting in a degradation in performance. Thermal modelling can only predict the structural integrity of construction materials in fire if it is given accurate inputs. Consequently, methods for the characterization of the thermal, physical, and mechanical behaviors of wood and wood-based composites are selected, designed, and benchmarked. The relevant thermal and physical responses characterized includes porosity, permeability and thermal diffusivity. Common construction materials (white pine board, medium density fiberboard and spruce 24) are characterized from room temperature to complete decomposition. The characterization techniques and processes are based on existing literature and relevant ASTM standards. To reduce the number of experiments required for future material characterization, estimates based upon the degree of decomposition and the measured values for the virgin and charred materials are used. For porosity and thermal diffusivity, these models allow values at intermediate temperatures to be estimated with measurements at room temperature and complete decomposition and thermogravimetric analysis (TGA). We find that permeability depends heavily on the microstructure of materials and should be measured independently at the conditions of interest. An additional important aspect of the performance of wood-based composites is the fracture behavior of wood/adhesive systems. Adhesive bonding enables many engineered wood products such as furniture and structural wood joints and the adhesive fracture toughness often determines the durability. The conventional characterization method for wood/adhesive fracture resistance relies on samples with machined grain angles designed to funnel cracks to the adhesive interface. This method of sample preparation is difficult and time-consuming for certain wood species. In this work, a practical and efficient method is developed to characterize adhesive fracture energy of adhesively bonded veneer systems. In the method, auxiliary aluminum adherends are bonded to the veneers in an effort to drive the crack to the wood/adhesive interface. The method is applied to rotary-peeled veneers and saw-cut veneers produced from three species of wood bonded with three commonly used adhesives. The new tests method yields a high interfacial failure rate and successfully identifies differences in the performance of the three adhesives. SPG (one species of the rotary-peeled veneers) demonstrates a rising R-curve behavior (an increase in the fracture toughness with crack length) when bonded on the loose side. This increase in fracture toughness is observed to be a result of adhesive-substrate interaction, which is a developing process zone behind the crack tip consisting of bridged wood ligaments. / Doctor of Philosophy / Construction materials exposed to elevated temperatures from fires may reach temperatures where the material decomposes from the original material to a char. Protected and unprotected structural timber products exposed to fires may exhibit this behavior resulting in a degradation of performance. Understanding the thermal and physical responses of these materials is crucial in evaluating the materials behavior in fire. Additionally, many wood-based products (such as furniture) rely on adhesive bonds. Consequently, their usefulness is determined by the performance of those bonds. In this work, methods are developed to measure key properties impacting the behavior of wood-based systems at elevated temperatures, such as that experienced in fires and when they are subjected to forces attempting to debond one wood material from another. These techniques are demonstrated on common building materials (white pine board, medium density fiberboard and spruce 24) and wood veneers from three different species bonded with three different adhesives. Mathematical models are developed to expand the use of the data beyond the specific conditions for which it is measured.