Evaluating the strengths of thick aluminum-to-aluminum joints with different adhesive lengths and thicknesses

Composite joints are often the weakest elements in composite structures. In this paper, we propose a modified version of the damage zone theory based on the yield strain ratio. We use this framework to predict failure loads for various adhesive joints. Thick aluminum-to-aluminum joint specimens with eight different adhesive lengths and four adhesive thicknesses were manufactured and tested. The strengths of different adhesive lengths could be predicted to within 15.4% using the damage zone ratio method. In addition, the strengths of joints that feature different adhesive thicknesses were predicted to within 16.3% using the damage zone ratio method.