Skip to main content

Advertisement

SpringerLink
Log in

Design and Analysis of a Novel Carbon Fiber Reinforced Polymer Sandwich Adhesive Joint

  • Published:
Applied Composite Materials Aims and scope Submit manuscript

Abstract

Composite sandwich structures are widely used in transport and energy applications because of their excellent specific strength and fatigue damage resistance. However, the mechanical properties of the joint area rely on the structural design. This paper proposes a novel carbon fiber-reinforced polymer sandwich joint in the context of a Formula Student monocoque. A stiffener is introduced to connect carbon fiber panels on both sides, and the geometry of the aluminum honeycomb connecting core is adjusted to improve the stress distribution in the joint panels. A finite element model under a three-point bending load is established based on the progressive damage model and the cohesive zone model. The mechanical properties were compared with conventional joints based on Formula Student three-point bending tests. Specimens were fabricated and tested using t700 carbon fiber prepreg and 3003 aluminum honeycombs to verify the joint’s performance and the accuracy of the finite element model. Experimental results showed that the three-point bending strength of the novel joint increased by 52.27%, and the stiffness increased by 101% compared to the conventional design. The simulated strength errors of the novel joint and the conventional joint were 4.66%, and 13.7%, respectively, and the failure modes were consistent with the experimental results, indicating the validity of the finite element model. The novel joint profile is less protruding than the conventional joint and could be widely used for joining or repairing automotive and aircraft components.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19

Similar content being viewed by others

Availability of Data and Materials

The data that support the findings of this study are available on request from the first author Yifei Wang. The data are not publicly available due to the studies are related to motorsports competitions, they contain information that may compromise the competitive advantage of the study participants in the competition.

References

  1. Al-Fatlawi, A., J´armai, K., Kov´acs, G.: Optimal design of a fiberreinforced plastic composite sandwich structure for the base plate of aircraft pallets in order to reduce weight. Polymers 13, 834 (2021). https://doi.org/10.3390/polym13050834

  2. KR, S., Anton, J., Spatenka, P., Sourkova, H.J.: Experimental studies on the influence of plasma treatment of polyethylene in carbon fiber composites: Mechanical and morphological studies. Polymers 14, 1095 (2022). https://doi.org/10.3390/polym14061095

  3. Kavimani, V., Gopal, P.M., Sumesh, K.R., & Elanchezhian, R.: Improvement on mechanical and flame retardancy behaviour of bio-exfoliated graphenefilled epoxy/glass fibre composites using compression moulding approach. Polym. Bull. 79, 6289–6307 (2022). https://doi.org/10.1007/s00289-021-03810-x

  4. Kavimani, V., Gopal, P.M., Sumesh, K.R., & Kumar, N.V.: Multi response optimization on machinability of sic waste fillers reinforced polymer matrix composite using taguchi’s coupled grey relational analysis. Silicon 14, 65–73 (2020). https://doi.org/10.1007/s12633-020-00782-x

  5. Khosravani, M.R., Zolfagharian, A., Jennings, M., Reinicke, T.: Structural performance of 3d- printed composites under various loads and environmental conditions. Polym. Test. 91, 106770 (2020). https://doi.org/10.1016/j.polymertesting.2020.106770

  6. Nakagawa, Y., Mori, K.I., Yoshino, M.: Laser-assisted 3d printing of carbon fibre reinforced plastic parts. J. Manuf. Process. 73, 375–384 (2022). https://doi.org/10.1016/j.jmapro.2021.11.025

  7. Amiri Delouei, A., Emamian, A., Sajjadi, H., Atashafrooz, M., Li, Y., Wang, L.P., Jing, D., Xie, G.: A comprehensive review on multi-dimensional heat conduction of multi-layer and composite structures: Analytical solutions. J. Therm. Sci. 30, 1875–1907 (2021). https://doi.org/10.1007/s11630-021-1517-1

  8. Savage, G.: Formula 1 composites engineering. Eng. Fail. Anal. 17, 92–115 (2010). https://doi.org/10.1016/j.engfailanal.2009.04.014

    Article  CAS  Google Scholar 

  9. Barca, I.: Strength calculations of the formula 1car survical cell. Technologia i Automatyzacja Montaz˙u 1, 3–13 (2022). https://doi.org/10.7862/tiam.2022.1.1

  10. Kupski, J., de Freitas, S. T.: Design of adhesively bonded lap joints with laminated cfrp adherends: Review, challenges and new opportunities for aerospace structures. Compos. Struct. 268, 113923 (2021). https://doi.org/10.1016/j.compstruct.2021.113923

  11. Zhang, H., Zhang, L., Liu, Z., Zhu, P.: Research in failure behaviors of hybrid single lap aluminum-cfrp (plain woven) joints. Thin-Walled Struct. 161, 107488 (2021). https://doi.org/10.1016/j.tws.2021.107488

  12. Qi, G., Chen, Y.-L., Richert, P., Ma, L., Schroeder, K.-U.: A hybrid joining insert for sandwich panels with pyramidal lattice truss cores. Compos. Struct. 241, 112123 (2020). https://doi.org/10.1016/j.compstruct.2020.112123

  13. Heslehurst, R.B.: Design and analysis of structural joints with composite materials. DEStech Publications Inc, Lancaster (2013)

    Google Scholar 

  14. Khosravani, M.R.: Influences of defects on the performance of adhesively bonded sandwich joints. Key Eng. Mater. 789, 45–50 (2018). https://doi.org/10.4028/www.scientific.net/KEM.789.45

    Article  Google Scholar 

  15. Baek, S.J., Kim, M.S., An, W.J., Choi, J.H.: Defect detection of composite adhesive joints using electrical resistance method. Compos. Struct. 220, 179–184 (2019). https://doi.org/10.1016/j.compstruct.2019.03.081

  16. Li, G., Lee-Sullivan, P., Thring, R.W.: Nonlinear finite element analysis of stress and strain distributions across the adhesive thickness in composite single-lap joints. Compos. Struct. 46, 395–403 (1999). https://doi.org/10.1016/S0263-8223(99)00106-3

    Article  Google Scholar 

  17. Adams, R.D.: Strength predictions for lap joints, especially with composite adherends. a review. J. Adhes. 30, 219–242 (1989). https://doi.org/10.1080/00218468908048207

  18. Zeng, Q.-G., Sun, C.: Novel design of a bonded lap joint. AIAA J. 39, 1991–1996 (2001). https://doi.org/10.2514/2.1191

    Article  Google Scholar 

  19. Xiaoquan, C., Baig, Y., Renwei, H., Yujian, G., Jikui, Z.: Study of tensile failure mechanisms in scarf repaired cfrp laminates. Int. J. Adhes. Adhes. 41, 177–185 (2013). https://doi.org/10.1016/j.ijadhadh.2012.10.015

    Article  CAS  Google Scholar 

  20. Zeng, H., Yan, R., Xu, L.: Failure prediction of composite sandwich l-joint under bending. Compos. Struct. 197, 54–62 (2018). https://doi.org/10.1016/j.compstruct.2018.05.022

  21. Toftegaard, H., Lystrup, A.: Design and test of lightweight sandwich t-joint for naval ships. Compos. A Appl. Sci. Manuf. 36, 1055–1065 (2005). https://doi.org/10.1016/j.compositesa.2004.10.031

    Article  CAS  Google Scholar 

  22. Toubia, E.A., Elmushyakhi, A.: Influence of core joints in sandwich composites under in-plane static and fatigue loads. Mater. Des. 131, 102–111 (2017). https://doi.org/10.1016/j.matdes.2017.06.009

    Article  Google Scholar 

  23. Tak´acs, L., Szab´o, F.: Ian effective method of modeling the deformation behavior of polymer sandwich structures with adhesive joints. Appl. Compos. Mater. 28, 1959–1978 (2021). https://doi.org/10.1007/s10443-021-09948-1

  24. Standardization, E.: Space engineering: Adhesive bonding handbook, ed. ecfs standardization. vol. Tech. Rep., ECSS-E-HB-32–21A (2011)

  25. Garrido, M., Correia, J.R., Keller, T., Branco, F.A.: Adhesively bonded connections between composite sandwich floor panels for building rehabilitation. Compos. Struct. 134, 255–268 (2015). https://doi.org/10.1016/j.compstruct.2015.08.080

  26. Cen, B., et al.: Mechanical behavior of novel gfrp foam sandwich adhesive joints. Compos. B Eng. 130, 1–10 (2017). https://doi.org/10.1016/j.compositesb.2017.07.034

  27. Ghazali, E., Dano, M.-L., Gakwaya, A., Amyot, C.-O.: Experimental and numerical studies of stepped-scarf circular repairs in composite sandwich panels. Int. J. Adhes. Adhes. 82, 41–49 (2018). https://doi.org/10.1016/j.ijadhadh.2017.12.008

    Article  CAS  Google Scholar 

  28. Xu, L., Kharghani, N., Li, M., Soares, C.G.: Design improvement of a composite-to-steel butt-joint based on finite element analysis. Ocean Eng. 238, 109771 (2021). https://doi.org/10.1016/j.oceaneng.2021.109771

  29. Masters, I., Evans, K.: Models for the elastic deformation of honeycombs. Compos. Struct. 35, 403–422 (1996). https://doi.org/10.1016/S0263-8223(96)00054-2

  30. Li, Z., Wang, D., Kang, Q.: The development of data acquisition system of formula sae race car based on can bus communication interface and closed-loop design of racing car. Wirel. Commun. Mob. Comput. 2021, 18 (2021). https://doi.org/10.1155/2021/4211010

  31. Stewart, R.: New mould technologies and tooling materials promise advances for composites. Reinf. Plast. 54, 30–36 (2010). https://doi.org/10.1016/S0034-3617(10)70110-7

  32. Castani´e, B., Bouvet, C., Ginot, M.: Review of composite sandwich structure in aeronautic applications. Compos. C Open Access 1, 100004 (2020). https://doi.org/10.1016/j.jcomc.2020.100004

  33. Sratong-on, P.: Structural design of a full-body composite monocoque chassis based on the type of carbon fiber fabrics. Tech. Rep., SAE Technical Paper (2022).

  34. Shams, S.S., El-Hajjar, R.F.: Overlay patch repair of scratch damage in carbon fiber/epoxy laminated composites. Compos. A 49, 148–156 (2013). https://doi.org/10.1016/j.compositesa.2013.03.005

    Article  CAS  Google Scholar 

  35. Sun, L., Tie, Y., Hou, Y., Lu, X., Li, C.: Prediction of failure behavior of adhesively bonded cfrp scarf joints using a cohesive zone model. Eng. Fract. Mech. 228, 106897 (2020). https://doi.org/10.1016/j.engfracmech.2020.106897

  36. Feldhusen, J., Warkotsch, C., Kempf, A.: Development of a mechanical technology for joining sandwich elements. J. Sandwich Struct. Mater. 11, 471–486 (2009). https://doi.org/10.1177/1099636209105378

    Article  Google Scholar 

  37. Haugum, H., Pløen, M.: Dimensjonering, analyse og testing av inserts i karbonfiber kompositt sandwich chassis. Master’s thesis, Institutt for produktutvikling og materialer (2014).

  38. Anandan, S., Dhaliwal, G., Ganguly, S., Chandrashekhara, K.: Investigation of sandwich composite failure under three-point bending: Simulation and experimental validation. J. Sandwich Struct. Mater. 22, 1838–1858 (2020). https://doi.org/10.1177/1099636218791162

    Article  Google Scholar 

  39. Zhang, H., Zhang, L., Liu, Z., Zhu, P.: Research in failure behaviors of hybrid single lap aluminum-cfrp (plain woven) joints. Thin-Walled Struct. 161, 107488 (2021). https://doi.org/10.1016/j.tws.2021.107488

  40. Hashin, Z.: Failure criteria for unidirectional fiber composites. J. Appl. Mech. 48, 846–852 (1981). https://doi.org/10.1115/1.3157744

    Article  Google Scholar 

  41. Ridha, M., Tan, V.B.C., Tay, T.E.: Traction–separation laws for progressive failure of bonded scarf repair of composite panel. Compos. Struct. 93, 1239– 1245 (2011). https://doi.org/10.1016/j.compstruct.2010.10.015

  42. Xiao, Y., et al.: The bending responses of sandwich panels with aluminium honeycomb core and cfrp skins used in electric vehicle body. Adv. Mater. Sci. Eng. 2018, 1838–1858 (2020). https://doi.org/10.1155/2018/5750607

Download references

Author information

Authors and Affiliations

  1. College of Automotive Engineering, Jilin University, Renmin Street, Changchun, 130000, Jilin, China

    Yifei Wang, Fei Wang & Da Wang

  2. School of Mechanical and Aerospace Engineering, Jilin University, Renmin Street, Changchun, 130000, Jilin, China

    Qianhui Xu & Kaiwei Ye

  3. College of Automotive Studies, Tongji University, Caoan Road, Shanghai, 201804, Shanghai, China

    Jinlong Hong & Bingzhao Gao

Authors
  1. Yifei Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Fei Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Qianhui Xu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Jinlong Hong
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Da Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Kaiwei Ye
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Bingzhao Gao
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Bingzhao Gao.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Appendix A

Appendix A

1.1 Mesh size sensitivity analysis

The SC8R shell element forms the skin of sandwich structures and joints. In order to study the influence of the mesh size on the simulation results in this model, the load–displacement curves of the three-point bending simulation were calculated when the mesh size changed from 0.5 mm to 2 mm, and the simulation time used was recorded, respectively. As can be seen from Fig. 20, when the cell size is 0.5 mm and 1 mm, the load–displacement curve is consistent with the experimental results, and the simulation results tend to converge. 1 mm mesh size can take into consideration both the requirements of calculation accuracy and calculation speed. With the increase of mesh size, the error of simulation results increases; when the mesh size is 2 mm, the results are not available.

Fig. 20
figure 20

Mesh size sensitivity analysis results

Full size image

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Wang, Y., Wang, F., Xu, Q. et al. Design and Analysis of a Novel Carbon Fiber Reinforced Polymer Sandwich Adhesive Joint. Appl Compos Mater 30, 791–813 (2023). https://doi.org/10.1007/s10443-023-10113-z

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s10443-023-10113-z

Keywords

Search

Navigation