Analysis of interfacial failure in AL / CFRP laminates with varying surface textures

Abstract Nowadays, AL/CFRP laminates are widely used in the fuselage structures of medium‐ to large‐sized aircraft due to their excellent performance, particularly in enhancing the stiffness and strength of wings. However, delamination at the interface can easily occur, limiting their performance. A unique interface design strategy is proposed to help fibers enter surface microstructure grooves. varied component interfaces have varied surface microstructures. Short beam strength tests compare component failure mechanisms and load‐bearing capacities with diverse surface microstructures and typical interface treatment procedures. The failure factor contour maps from finite element computations demonstrate how failure modes and load‐bearing capacity evolve. The results show that components with surface microstructures transition from interfacial failure at the interface of the two materials to cohesive failure within the composite material, improving load‐bearing capacity by up to 110%. The shape and number of surface microstructures affect component failure mechanisms and load‐bearing capacity. Wavy failure surfaces occur on rectangular specimens. The failure mode change is caused by surface microstructures shifting the highest failure factor from the interface to the interior of the CFRP. Highlights The investigation of interface design, wherein the texture direction aligns with the primary force direction and fiber orientation, has been conducted for the first time. The combination of fracture morphology on the cross‐section and damage factor contour maps explains the damage mechanism of various damage modes. The tooth shape and number of teeth have an important effect on both the damage pattern and the load‐carrying capacity. The optimal configuration has a 110% increase in load capacity compared to the original configuration.