Testing Composite-to-Metal Tubular Lap Joints

Abstract

Procedures were developed to fabricate, nondestructively evaluate, and mechanically test composite-to-metal tubular joints. The axially loaded tubular lap joint specimen consisted of two metal tubes bonded within each end of a fiberglass composite tube. Joint specimens with both tapered and untapered aluminum adherends and a plain weave E-glass/epoxy composite were tested in tension, compression, and flexure. Other specimens with tapered and untapered steel adherends and a triaxially reinforced E-glass/epoxy composite were tested in tension and compression. Test results include joint strength and failure mode data. A finite element analysis (FEA) of the axially loaded joints explains the effect of adherend geometry and material properties on measured joint strength. The flexural specimen was also analyzed; calculated surface strains are in good agreement with measured values, and joint failure occurs in the region of calculated peak peel stress.