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Experimental Study of Adhesively Bonded Single Lap Joint Behaviour in CFRP-to-CFRP, Al-to-Al, and CFRP-to-Al Configurations

Experimental Study of Adhesively Bonded Single Lap Joint Behaviour in CFRP-to-CFRP, Al-to-Al, and CFRP-to-Al Configurations

Abstract

This study evaluates the tensile performance of single-lap joints with three configurations: CFRP-to-CFRP, Al-to-Al, and CFRP-to-Al. The effect of CFRP and aluminum adherends on joint strength was analyzed based on surface characteristics and mechanical properties. CFRP substrates were fabricated using vacuum-assisted resin infusion with vinyl ester resin and unidirectional carbon fibers, while aluminum plates were cut to ASTM D5868 standards. Epoxy adhesive was employed, and surface preparation included 800-grit sanding to enhance bond quality. Surface roughness, wettability, and morphology were characterized using a surface roughness tester, contact angle, and atomic force microscopy measurements. Sanding significantly reduced surface roughness (Ra) for CFRP from 6.48 ± 0.24 μm to 1.49 ± 0.19 μm, improving surface wettability. Aluminum exhibited lower contact angles than CFRP, reflecting its distinct surface properties. Tensile tests of the epoxy adhesive revealed an ultimate tensile strength of 54.30 ± 2.20 MPa and a tensile modulus of 2.21 ± 0.08 GPa, confirming its suitability for SLJs. Lap shear tests demonstrated that CFRP-to-CFRP joints achieved the highest average shear strength (5.05 ± 0.64 MPa), followed by Al-to-Al (3.03 ± 0.57 MPa) and CFRP-to-Al (3.52 ± 0.75 MPa). The CFRP-to-Al configuration exhibited the highest variability due to material incompatibilities. Failure analysis indicated mixed adhesive and cohesive failure modes across all configurations, with CFRP-to-CFRP joints showing superior bond consistency. These findings highlight the critical role of material compatibility and surface treatment in optimizing SLJ performance for composite and dissimilar material joints.

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selected citations
These citations are derived from selected sources.
This is an alternative to the "Influence" indicator, which also reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Citations provided by BIP!
popularity
This indicator reflects the "current" impact/attention (the "hype") of an article in the research community at large, based on the underlying citation network.
BIP!Popularity provided by BIP!
influence
This indicator reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Influence provided by BIP!
impulse
This indicator reflects the initial momentum of an article directly after its publication, based on the underlying citation network.
BIP!Impulse provided by BIP!
0
Average
Average
Average
gold