Single-lap joints of similar and dissimilar adherends bonded with a polyurethane adhesive used in the automotive industry

Abstract The mechanical performances of single-lap joints between similar and dissimilar adherends bonded with a bi-component polyurethane adhesive have been studied in the present work. The substrate materials include both carbon fibre reinforced composite material (CRFP) and painted metal substrates (PMS). The following substrate combinations were tested: CFRP/CFRP, PMS/PMS, and CFRP/PMS. Two adhesive overlaps, 12 mm and 24 mm, with a fixed thickness were studied to assess the mechanical behaviour of the adhesive joints. The experimental results have been used to construct a finite element model of the single lap joint tests. The objective is to determine the material cohesive properties, in particular the maximum shear stress and the corresponding energy release rate, of the adhesive layer for each retained combination of substrates. An optimization scheme based on transient nonlinear finite element analysis has been here considered, where cohesive parameters of the adhesive layer are handled as design variables. Material parameters are firstly identified for the 12 mm overlap, minimizing the discrepancy between the experimental and numerical force-displacement curves. Then, to validate the obtained properties, results of the 24 mm overlap single lap joint tests are used. The comparison between the experimental and numerical results shows a very good agreement.