LAUSR

Abstract In this paper, the failure behaviors of the hybrid joint (HJ) of plain woven carbon fiber reinforced plastic (CFRP) and aluminum alloy were systematically studied by quasi-static tensile experiments and a new refined simulation. Experimental results showed that the HJ failure has a typical three-stage feature: first, the bond line and the rivet share the load; and then the bond line gradually fractures; finally, the rivet bears the load alone. It is also concluded that HJs are superior to bonded joints and riveted joints in strength and energy absorption. As for the simulation model, a damage mechanics model considering shear nonlinearity and distinguishing failure modes for plain woven CFRP was constructed, added with a cohesive behavior for the bond line and a bilinear elastoplastic hardening model for the aluminum alloy substrate and the stainless steel rivet. Based on the simulation model, the three-stage feature was successfully simulated. Furthermore, the simulation results shed new light on the failure mechanisms of the HJs as well as the influences of clamping force and interference-fit on the HJ mechanical properties. In conclusion, this research helps to understand the failure behaviors and provides guidance for the design and manufacture of HJs.