Assessment of geometric parameters on the tensile behavior of hybrid (rivet‐adhesive) aluminum‐composite joints

Abstract The hybrid adhesive‐rivet joints offer very good behavior in bonding. This bond is then reinforced by a rivet, adding significant mechanical strength and preventing separation under stress. In this research, composite‐aluminum, hybrid (adhesive‐rivet) joints were investigated. Two types of composites were used in this research: unidirectional and woven fiber types. Hybrid (adhesive‐rivet) joints made in two distinct types: single and double rivet joints. Various types of simple and hybrid (rivet adhesive) joint with one or two rivets are investigated and effect of them on strength of various composite substrate are investigated. The study advances knowledge by demonstrating how combining adhesive and rivet reinforcements optimizes joint strength and energy absorption in composite‐aluminum structures. It was observed that adhesive joint specimens of Al–glass fiber reinforced plastic (GFRP) with a 45‐degree unidirectional fiber angle (Al–CU—45) have the lowest strength than 0° and 90° UD fiber angles (Al–CU—0 and 90) and the tensile strength of hybrid adhesive joints for woven GFRP composites (Al–CW) is better than joints with 45‐degree woven GFRP composites. Two‐rivet joints with 0°/90° fibers exhibited 30% higher load capacity than ±45° fibers, while also absorbing 20% more energy compared to single‐rivet joints. The maximum fracture force in the single‐rivet specimen with 0° fiber orientation has improved by 42.8% compared to the single‐rivet specimen with 90° fiber orientation. Finally, fractography of specimens were done and macroscopic and microscopic investigation of fracture surface of samples are done. The scanning electron microscopy images shows detailed view of the fracture surfaces and effect of rivets on the surface of fracture. Highlights Adhesive joints: 0°/90° GFRP outperformed 45° fibers in tensile strength. Fracture force: Al–CU‐0° fibers showed the highest force in hybrid joints. Displacement: Al–CU‐45° fibers had the highest failure displacement. Energy absorption: Al–CU‐45° fibers excelled in both adhesive and hybrid joints. SEM: 0/90° fibers showed fewer cracks, while 45° fibers had weaker matrices.