Composite Structures 53 (2001) 213221

www.elsevier.com/locate/compstruct

Eects of stacking sequence and clamping force on the bearing strengths of mechanically fastened joints in composite laminates
Heung-Joon Park *
Department of Mechanical Engineering, ME3028, Korea Advanced Institute of Science and Technology, Science Town, Taejon 305-701, South Korea

Abstract The weakest parts of a composite laminate structure are often the joints. Hence the need to design reliable and ecient loadcarrying joints has become increasingly important and the eects of stacking sequence and clamping force on joint strengths have to be claried. In this study, the eects of stacking sequence and clamping force on delamination bearing strength and ultimate bearing strength of mechanically fastened joints (pinned and bolted) in carbon/epoxy composite laminates were examined using the acoustic emission (AE) technique. Two orthotropic and three quasi-isotropic laminate lay-up congurations and four clamping forces were examined. Based on the experiments, the eects of stacking sequence and clamping force on joint strengths were systematically investigated. Guidelines for eective stacking sequences and maximum clamping forces for mechanically fastened joints in composite laminates are suggested based on delamination bearing strength and ultimate bearing strength. 2001 Published by Elsevier Science Ltd.
Keywords: Composite laminate; Stacking sequence; Clamping force; Mechanically fastened joint; Delamination bearing strength; Ultimate bearing strength; Acoustic emission (AE) technique

1. Introduction As ber-reinforced composite laminate materials have become more extensively used in an aircraft, missiles and spacecraft, the need for reliable and ecient load-carrying joints has become increasingly important. The designer has two basic techniques for joining components of ber-reinforced composite materials: mechanical fastening and adhesive bonding. In practical applications, it is often unavoidable to resort to mechanical joints to join composite laminates with other structural components or to access periodically to the interior of the structure, such as electronic components or mechanical subsystems in an aircraft, missiles and spacecraft. The local contact between the mechanical fastener and the composite laminate may induce large strains, high stress concentrations and delamination failure near the contact edge of a hole and eventually, catastrophic failure of the laminate. Numerous studies [126] have demonstrated that such strain, stress and failure can occur in mechanical joints of composite laminates. However, most studies [124] have been reported on the
*

Tel.: +82-42-869-5028; fax: +82-42-869-3210. E-mail address: hjpark@imhp.kaist.ac.kr (H.-J. Park).

mechanical behavior of mechanical composite joints in which the eects of lateral constraints and clamping force were ignored. Little work has been published on the eects of clamping pressure. Marshall et al. [25] showed the importance of the clamping ratio, stacking sequence and clamping type to have a fundamental inuence on the magnitude of the interlaminar normal stress local to pin-loaded and bolted holes in 0=90S and 90=0S laminates. Oh et al. [26] investigated the optimum bolted joints for hybrid composite laminates composed of glass/epoxy and carbon/epoxy considering the design parameters of stacking sequence, the ratio of glass/epoxy to carbon/epoxy, the outer diameters of washers and the clamping pressure. Most of the previous experimental works [1,2,14,15,20,22,26] have been restricted to ultimate bearing strengths of mechanically fastened composite joints. The eects of stacking sequence and clamping force on the delamination bearing strengths of mechanically fastened joints in composite laminates have not been examined thoroughly. The weakest parts of a composite laminate structure are often the joints; therefore, the need to design reliable and ecient loadcarrying joints has attracted a substantial amount of attention and the eects of stacking sequence and clamping force on joint strengths have to be claried.

0263-8223/01/$ - see front matter 2001 Published by Elsevier Science Ltd. PII: S 0 2 6 3 - 8 2 2 3 ( 0 1 ) 0 0 0 0 5 - 8

214

H.-.J. Park / Composite Structures 53 (2001) 213221

In this study, the eects of stacking sequence and clamping force on the delamination bearing strength and the ultimate bearing strength of mechanically fastened joints (pinned and bolted) in carbon/epoxy composite laminates were examined using acoustic emission (AE) and a loaddisplacement technique. The AE test technique was used to detect the onset of delamination failure in composite laminates. Two orthotropic and three quasi-isotropic laminate lay-up congurations and four clamping forces were examined. Guidelines for effective stacking sequences and maximum clamping forces for mechanically fastened joints in composite laminates are described based on delamination bearing strength and ultimate bearing strength.

pressure is not applied in Figs. 2 and 3, the joint becomes a pin joint. Tables 1 and 2 show the stacking sequences and the clamping forces, respectively. In Table 1, lay-ups A, B and C are the quasi-isotropic laminates commonly used for the design of composite laminates, and lay-ups D and E are the typical orthotropic specimens. Five specimens were tested for each case. The ply angle of 0 coincides with the loading direction. In Table 2, the relationship between the bolt clamping torque, T N m

2. Experimental The joint specimen tested was carbon/epoxy HT145/ RS1222 made by hot pressing of prepreg layer (HFG). In this work, the specimen geometry was designed to induce bearing failure. For this purpose, both the ratios of width-to-diameter and edge distance-to-diameter were set to be 5. The geometry of the specimen is shown in Fig. 1. A glass/epoxy composite was used for the tabs on the carbon/epoxy composite specimens, and the tensile tests were performed using the loading xture illustrated in Fig. 2. The bolt with nominal diameter of 1/4 in (6.35 mm) was used for the mechanically fastened specimens. Used washers that had the inner diameter coinciding with the bolt nominal diameter, the outer diameter of 12.5 mm and the thickness of 5 mm. The testing machine was an Instron Universal Machine (Type 8502) with a test speed of 1 mm/min. A Physical Acoustic Corporation (PAC) Spartan 2000 AE instrument was used. The operating parameters were: a resonance transducer (125 kHz), Micro 30; a xed gain 40 dB pre-amplier and 30 dB main-amplier, a system moving threshold level of 45 dB and a lter of 100600 kHz. Fig. 3 shows a photograph of the specimen and the specimen set-up, in which four AE transducers were attached around the hole. Fig. 4 shows the global layout of the test. When the washers are removed and clamping

Fig. 2. Set-up of mechanically fastened joint (drawing).

Fig. 1. Geometry of the specimen.

Fig. 3. Set-up of mechanically fastened joint (photograph).

H.-.J. Park / Composite Structures 53 (2001) 213221

215

Fig. 4. Schematic diagram of experimental lay-out.

and the bolt clamping pressure, rpress (MPa) can be calculated from the following equation [26,27]: rpress or rpress MPa 8:648T N m; where K is the torque factor (0.2 on average), D is the nominal bolt diameter (mm) and DW is the outer diameter (mm) of the washer. In Table 2, the torque value, 60 lbf-in (6.78 N m) is the nominal clamping torque of the steel (AISI4130) bolt with the nominal diameter of 1/ 4 in (6.35 mm) and the tensile ultimate strength of 125 145 ksi (8621000 MPa).
Table 1 Stacking sequences of the specimens Specimen ID A B C D E Stacking sequence 903 = 453 = 453 =03 S 903 =03 = 453 = 453 S 03 = 453 = 453 =903 S 906 =06 S 06 =906 S Remarks

1000T 2 p=4KDD2 W D

Quasi-isotropic (pinned and bolted joint) Orthotropic (pinned joint)

Table 2 Clamping forces Type Pinned joint Bolted joint Clamping torque (lbf-in, N m) No clamping Low (5.3, 0.60) Middle (30, 3.39) Nominal (60, 6.78) Clamping pressure (MPa) 0.0 5.2 29.3 58.6

The AE parameters used in this study are hits, counts, energy and their accumulative values and amplitude. Typical graphs of the AE parameters measured in a test are shown in Fig. 5. The ``PARAM. #1'' in the horizontal axis of Fig. 5 indicates the test load applied, which has the unit of kgf and was converted from the loading time measured. In Fig. 5, the verticalhorizontal axes of the graphs are energyamplitude (Graph #1), amplitudeload (Graph #2), hitsload (Graph #3), energyload (Graph #4), countsload (Graph #5), accumulative hitsload (Graph #6), accumulative energy load (Graph #7), and accumulative countsload (Graph #8), from the bottom graph, respectively. A typical loaddisplacement curve is plotted in Fig. 6. The graphs and curve of Figs. 5 and 6 were measured in the same test. As shown in the amplitudeload graph (Graph #2) in Fig. 5, during the loading process AE signals with amplitude below 60 dB were scarcely detected when the loading is low, and AE signals with amplitude above 60 dB abruptly increased after the load of 700 kgf. As shown in the energyamplitude graph (Graph #1) in Fig. 5, AE signals with amplitude below 60 dB have a small energy along with AE signals with amplitude above 77 dB. All AE parameters (Graphs #28) in Fig. 5 suddenly increase after the load, 700 kgf. These facts imply the following. The AE signals with amplitudes below 60 dB and low energy were related to the damage of matrix cracking; the AE signals with amplitudes above 60 dB and much smaller energy were related to the damage of ber breakage; the AE signals with amplitude of 6077 dB and high energy were related to the delamination damage. The initial delamination of the laminate specimen occurs at the load, 700 kgf. We dene the load at which the initial delamination occurs, to be the ``delamination onset load''. As shown in Fig. 6, the

216

H.-.J. Park / Composite Structures 53 (2001) 213221

Fig. 5. Typical graphs of AE parameters measured in a test (Graph #1: energyamplitude; Graph #2: amplitudeload; Graph #3: hitsload; Graph #4: energyload; Graph #5: countsload; Graph #6: accumulative hitsload; Graph #7: accumulative energyload; Graph #8: accumulative counts load).

maximum ultimate failure load of the laminate specimen was 820 kgf. We dene the load at which the ultimate failure occurs to be the ``ultimate failure load''. As shown in Fig. 5, the AE parameters (hit, energy and count; Graphs #35) show the repeated step-like decrease and increase after the delamination onset load, and the AE parameters increase abruptly at the ultimate failure load, 800 kgf. In Fig. 5, the AE parameters (Graphs #28) appear even after the ultimate failure

load, because the load of the horizontal axis is converted from the loading time measured as mentioned above. 3. Results and discussion The ``delamination bearing strength, rd '' and the ``ultimate bearing strength, ru '' of the joint in laminate are dened by the following equations, respectively:

H.-.J. Park / Composite Structures 53 (2001) 213221

217

Fig. 8. Average values of ultimate bearing strengths and delamination bearing strengths of pinned joint from each laminate specimen. Fig. 6. A typical loaddisplacement curve.

rd

Pd ; Dt

ru

Pu ; Dt

where Pd and Pu are the delamination onset load and the ultimate failure load, respectively, D is the hole diameter, and t is the thickness of the laminate. 3.1. Pinned joint test Fig. 7 shows the delamination bearing strengths and the ultimate bearing strengths of pinned joint with respect to the stacking sequence. In Fig. 7, the lower data group represents the delamination bearing strengths, and the upper data group the ultimate bearing strengths, while the open symbols of each data group represent the average values of each data group. For comparison, the average values of the delamination and the ultimate bearing strengths of the pinned joint with respect to the stacking sequence are shown in Fig. 8. Comparing the results of the pinned joint test of typical orthotropic composite laminates with stacking sequences of lay-up D 906 =06 S and lay-up E 06 =906 S ,

the both lay-ups have almost same ultimate bearing strengths, while the lay-up D has the delamination bearing strength about two times stronger than that of the lay-up E. Thus, the stacking sequence of the lay-up D with 90 layers on the surface will be advantageous than the lay-up E with 0 layers on the surface, in the aspect of delamination failure of composite laminates on bearing plane. Comparing the results of the pinned joint test for the typical quasi-isotropic composite laminates with the stacking sequences of lay-up A 903 = 453 =03 S , lay-up B 903 =03 = 453 S , and lay-up C 03 = 453 =903 S , the lay-up A has the highest ultimate bearing strength, and the lay-up C has the lowest one. On the other hand, the lay-up B has the highest delamination bearing strength and the lay-up C has the lowest one. For the orthotropic and the quasi-isotropic laminates, the delamination bearing strengths of the lay-up with 90 layers on the surface are stronger than the lay-up with 90 layers located at the center of laminate. From the results of this investigation, it is found that the roll of 90 layer is important for the delamination bearing strength of composite laminate, and we might well conclude that the stacking sequence of lay-up B, which has the highest bearing strength and the second highest ultimate bearing strength, should be preferred from the viewpoint of its characteristics of the fail-safe delamination failure. 3.2. Bolted joint test The bolted joints, which had the bolt clamping pressures of three types as shown in Table 2, were tested for the lay-ups, A 903 = 453 =03 S , B 903 =03 = 453 S , and C 03 = 453 =903 S , typical quasi-isotropic stacking sequences. When the bolt is clamped at the joint of laminate, the clamping torque of the bolt presses the laminate under washer, and the delamination on the loaded side of the joint hole in the laminate is suppressed. In this case, the location of laminate delamin-

Fig. 7. Ultimate bearing strengths (upper data groups) and delamination bearing strengths (lower data groups) of pinned joint from each laminate specimen.

218

H.-.J. Park / Composite Structures 53 (2001) 213221

ation moved to the outer edge of constrained region, i.e. outer edge of the washer. As the clamping pressure increased, the movement of delamination toward outer edge of the washer is more noticeably observed, as shown in Fig. 9. Figs. 1012 show the delamination bearing strengths and ultimate bearing strengths of the bolted joints with respect to the stacking sequence for the clamping pressures, 5.2, 29.3 and 58.6 MPa, respectively. In Figs. 10 12, the lower data group represents the delamination bearing strengths, and the upper data group represents the ultimate bearing strengths, while the open symbols of each data group represents the average values of each data group. The average values of the ultimate bearing strengths and the delamination bearing strengths for the quasiisotropic lay-ups with clamping pressures, 0 MPa (pinned joint), 5.2, 29.3, and 58.6 MPa are shown in Figs. 13 and 14, respectively. The variations of the average values of the ultimate bearing strengths and the delamination bearing strengths with respect to the clamping pressure for the each stacking sequence are shown in Figs. 15 and 16, respectively. Comparing the test results of the pinned joint (Fig. 7) and the bolted joint (Figs. 1012), the deviations of the experimental values of bolted joint were reduced, because the lateral constraint of the bolted joint reduces the uncertainties in loading mechanism including the contact between the laminate and the fastener. As

shown in Figs. 13 and 14, the ultimate bearing strengths and the delamination bearing strengths of the bolted joint are higher than those of the pinned joint. The ultimate bearing strengths are almost two times higher than the delamination bearing strengths for the bolted joint. The dierence between the ultimate bearing

Fig. 10. Ultimate bearing strengths (upper data groups) and delamination bearing strengths (lower data groups) of bolted joint (clamping pressure, 5.2 MPa) from each laminate specimen.

Fig. 11. Ultimate bearing strengths (upper data groups) and delamination bearing strengths (lower data groups) of bolted joint (clamping pressure, 29.3 MPa) from each laminate specimen.

Fig. 9. Photographs of specimens after experiment (the white parts of arc shape around the holes are the locations of laminate delamination, which are the outer edges of constrained region, i.e. outer edges of the washers).

Fig. 12. Ultimate bearing strengths (upper data groups) and delamination bearing strengths (lower data groups) of bolted joint (clamping pressure, 58.6 MPa) from each laminate specimen.

H.-.J. Park / Composite Structures 53 (2001) 213221

219

Fig. 13. Average values of ultimate bearing strengths from each laminate specimen. Fig. 15. Variations of the average values of the ultimate bearing strengths with respect to the clamping pressure.

Fig. 14. Average values of delamination bearing strengths from each laminate specimen.

strengths and the delamination bearing strengths of the bolted joint is more noticeable compared with the pinned joint (Fig. 8). The reason is that the clamping pressure of the bolted joint suppressed the delamination onset and continuously suppressed the propagation of the delamination defect even after the onset. Thus, due to this clamping pressure, the failure mode changes from the catastrophic one to the progressive one. Consequently, the clamping pressure will increase the delamination and the ultimate bearing strengths of the joints in laminates. As shown in Figs. 1014, the trend of variations of the ultimate and the delamination bearing strengths of bolted joints with respect to the stacking sequence is similar to that of pinned joints, which are independent of the magnitude of clamping pressure. Comparing the results of the bolted joint test in the typical quasi-isotropic composite laminates with the stacking sequences of lay-ups, A 903 = 453 =03 S , B 903 =03 = 453 S , and C 03 = 453 =903 S , the lay-up A has the highest ultimate bearing strength, and the lay-up C has the lowest one.

Fig. 16. Variations of the average values of the delamination bearing strengths with respect to the clamping pressure.

On the other hand, the lay-up B has the highest delamination bearing strength and the lay-up C has the lowest one. The delamination bearing strengths of the lay-up with 90 layers on surface are stronger than the one with 90 layers located at the center of laminate. Thus, similar to the pinned joint case, the stacking sequence of lay-up B, which has the highest bearing strength and the second highest ultimate bearing strength, should be preferred from the viewpoint of its characteristics of the fail-safe delamination failure. As shown in Figs. 15 and 16, as the clamping pressure increased, the ultimate bearing strength undergoes a sti increase while the delamination bearing strength shows a relatively progressive increase, which is independent of stacking sequence. With the small

220

H.-.J. Park / Composite Structures 53 (2001) 213221

clamping pressure of only about 0.1% of nominal bolt clamping, the ultimate bearing strengths is almost doubled. The signicant increase in ultimate bearing strength results from the eect of lateral boundary constraint by bolt head, washer and nut, rather than the eect of the clamping pressure. However, the clamping pressure directly inuences the increase of the delamination bearing strength. Fig. 15 shows that the ultimate bearing strength versus the clamping pressure becomes quickly saturated as compared with the delamination bearing strength of Fig. 16. It is noteworthy that the ultimate bearing strengths does not increase after the saturated (nominal) bolt clamping pressure, as shown in Fig. 15. Therefore it is shown that the clamping torque of bolted joints in composite laminates should not exceed the saturated bolt clamping pressure, i.e. excessive clamping pressure may induce compressive failure of the composite laminate. 4. Conclusion The eects of stacking sequence and clamping pressure on the delamination and ultimate bearing strengths of mechanically fastened joints (pinned and bolted) in composite laminates have been examined experimentally. AE test technique was used to detect the onset of delamination failure of composite laminates. Based on experimental evidence the following conclusions are made: 1. The stacking sequence and clamping pressure have a great inuence on the delamination and the ultimate bearing strengths of mechanically fastened joints in composite laminates. 2. Comparing the results of pinned joint testing of typical orthotropic composite laminates with stacking sequences of 906 =06 S and 06 =906 S , shows that both lay-ups have almost same ultimate bearing strengths, while the lay-up 906 =06 S has the delamination bearing strength about two times stronger than that of the lay-up 06 =906 S . Thus, the stacking sequence of the lay-up 906 =06 S with 90 layers on the surface will be more advantageous than the lay-up 06 =906 S with 0 layers on the surface, in the aspect of delamination failure of composite laminates on bearing plane. 3. The trend of variations of the ultimate and the delamination bearing strengths of bolted joints with respect to the stacking sequence is similar to that of pinned joints. Comparing the results of pinned and bolted joint tests for typical quasi-isotropic composite laminates with stacking sequences of 903 = 453 =03 S , 903 =03 = 453 S , and 03 = 453 =903 S , shows that the lay-up 903 = 453 =03 S has the highest ultimate bearing strength and the lay-up 903 =03 = 453 S has the second highest one. On the other hand, the layup 903 =03 = 453 S has the highest delamination

bearing strength. Thus the stacking sequence of 903 =03 = 453 S , which has the highest delamination bearing strength and the second highest ultimate bearing strength, should be preferred from the viewpoint of its characteristics of the fail-safe delamination failure. 4. The 90 layers play an important role in the delamination bearing strength of composite laminates. The delamination bearing strength of the lay-up with 90 layers on the surface is stronger than the one with 90 layers located at the center of laminate. 5. The lateral clamping pressure suppresses the onset of delamination and continuously suppresses the propagation of interlaminar cracks. The failure mode changes from a catastrophic one to a progressive one. Consequently, the lateral clamping pressure increases both the delamination and ultimate failure strengths of bolted joints in composite laminates. 6. As the clamping pressure increases, the ultimate bearing strength shows a signicant increase toward saturation, while the delamination bearing strength shows a progressive increase. The ultimate bearing strengths does not increase after the saturated bolt clamping pressure. Hence, it is desirable that the clamping torque of a bolted joint in a composite laminate should not exceed the saturated bolt clamping pressure.

References
[1] Quinn WJ. The eect of stacking sequences on the pin-bearing in glass bre reinforced plastic. J Compos Mater 1977;11:13945. [2] Hart-Smith LJ. Fibrous composites in structural design. New York: Plenum Press; 1980. [3] Agarwal BL. Static strength prediction of bolted joint in composite material. AIAA J 1980;18(11):13715. [4] Wong CMS, Matthews FL. A nite element analysis of single or two hole bolted joints in bre reinforced plastic. J Compos Mater 1981;15:48191. [5] Pradhakaran R. Photoelastic investigation of bolted joints in composites. Composites 1982;13:2536. [6] Rowlands RE, Rahman MU, Wilkinson TL, Chiang YI. Singleand multiple-bolted joints in orthotropic material. Composites 1982;13:2739. [7] York JL, Wilson DW, Pipes RB. Analysis of the net tension failure mode in composite bolted joints. J Reinf Plastics Compos 1982;1:14152. [8] Chang FK, Scott RA, Springer GS. Strength of mechanically fastened composite joints. J Compos Mater 1982;16:47094. [9] Chang FK, Scott RA, Springer GS. Failure of composite laminates containing pin loaded holes method of solution. J Compos Mater 1984;18:25578. [10] Mangalgiri PD. Pin-loaded holes in large orthotropic plates. AIAA J 1984;22:147884. [11] Naik RA, Crews Jr. JH. Stress analysis method for a clearance t bolt under bearing loads. AIAA J 1986;24:134853. [12] Chang FK. The eect of pin loaded distribution on strength of pin-loaded holes in laminated composites. J Compos Mater 1986;20:4018. [13] Eriksson LI. Contact stresses in bolted joints of composite laminates. Compos Struct 1986;6:5775.

H.-.J. Park / Composite Structures 53 (2001) 213221 [14] Collings TA. Experimentally determined strength of mechanically fastened joints. In: Matthews FL, editor. Joining bre-reinforced plastics. New York: Elsevier; 1987. [15] Tsai MY, Morton J. Stress and failure analysis of a pin-loaded composite plate : an experimental study. J Compos Mater 1990;24:110121. [16] Rahman MU, Rowlands RE. Finite element analysis of multiplebolted joints in orthotropic plates. Comput Struct 1993;46(5):859 67. [17] Zuiker JR. Analysis of a pin-loaded viscoplastic plate. Comput Struct 1995;56:295302. [18] Chen WH, Lee SS. Numerical and experimental failure analysis of composite laminates with bolted joints under bending. J Compos Mater 1995;29:1596612. [19] Chen WH, Lee SS, Yeh JT. Three-dimensional contact stress analysis of a composite laminate with bolted joint. Comput Struct 1995;30:28797. [20] Hamada H, Haruna K, Maekawa ZI. Eect of stacking sequences on mechanically fastened joint strength in quasi-isotropic carbonepoxy laminates. J Compos Technol Res 1995;17(3):24959.

221

[21] Hamada H, Maekawa ZI. Strength prediction of mechanically fastened quasi-isotropic carbon/epoxy joins. J Compos Mater 1996;30(14):1596612. [22] Wang HS, Hung CL, Chang FK. Bearing failure of bolted composite joints. Part I: experimental characterization. J Compos Mater 1996;30(12):1284313. [23] Hung CL, Chang FK. Bearing failure of bolted composite joints. Part II: model and verication. J Compos Mater 1996;30(12):1359400. [24] Ko HY, Kwak BM. Contact analysis of mechanically fastened joints in composite laminates by linear complementary problem formulation. Compos Struct 1998;40:187200. [25] Mashall IH, Arnold WS, Wood J. Observations on bolted connections in composite structures. Compos Struct 1989;13:13351. [26] Oh JH, Kim YG, Lee DG. Optimum bolted joints for hybrid composite materials. Compos Struct 1997;38(14):32947. [27] Edwards Jr. KS, McKee RB. Fundamentals of mechanical component design. New York: McGraw-Hill; 1991.