Optimum design of co-cured steel–composite tubular single lap joints under axial load

Abstract In this paper, an optimum design method for co-cured steel-composite tubular single lap joints under axial load is proposed based on a failure model which incorporates the nonlinear mechanical behavior of the steel adherend and the failure mode of joints such as composite adherend failure and steel adherend failure. The design parameters considered were the test temperature, the stacking sequence of the composite adherends, the thickness ratio of the steel adherend to the composite adherend, and the existence of scarf in the steel adherend. Stress analysis of the cocured steel-composite tubular single lap joints was performed considering the nonlinear mechanical behavior of the steel adherend, and the fabrication residual thermal stress and thermal degradation of the composite adherend. The method developed may be employed in the joining of hybrid composite structures such as golf clubs and automotive composite propeller shafts in which a carbon/epoxy shaft has normally been bonded to a metal shaft with epoxy adhesives. Keywords: CO-CURED STEEL-COMPOSITE TUBULAR SINGLE LAP JOINTFAILURE MODELFAILURE MODEADHEREND NONLINEAR MECHANICAL BEHAVIORAXIAL LOAD-BEARING CAPABILITYRESIDUAL THERMAL STRESSTHERMAL DEGRADATION