Verification steps in the analysis of bonded joints:

1. Recalculate stress distribution of the test sample (see example below); normally same adhesive tested at RT
2. Determine peak stress at the edge of the sample
3. Calculate stress distribution in the new joint
4. Demonstrate positive margin of safety MoS=(Smaxsample/(Smaxjoint*Jult))-1
Safety factor Jult=1.5 to 2.0
5. Note: test sample needs to be similar or stiffer than the new joint (Kt,mech less-equal than in new joint)
6. Verification of bonded joints under extreme temperatures (outside qualification temperatures of adhesive) needs testing at these temperatures
7. Warning: in case of CFRP the out-of-plane skin strength (similar to 90 strength of UD) can be very and thus failure of the bonding occurs in the first layer due to out-of-plane stres

Liner-elastic Analysis of Standard Joint under Test Loads; EA9321 acc.to ASTM D 1002

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

E-modulusthickness
70000
1.6
70000
1.6
0.1
12.7
350 Smean=
Kt,mech=
0
0.254
0.508
0.762
1.016
1.27
1.524
1.778
2.032
2.286
2.54
2.794
3.048
3.302
3.556
3.81
4.064
4.318

76.91922
68.92085
61.76897
55.37575
49.66266
44.55953
40.00368
35.93917
32.31606
29.08986
26.22095
23.67409
21.418
19.42496
17.6705
16.13307
14.7938
13.63622

CTE
G-modulus
0.00E+00
0.00E+00
1065

E*T
Ce
R
lambda
Fth
Fth0
112000
56000 0.190179 0.436095 0.00E+00 8.004302
112000
max. Fthermal=
0

27.55906
2.791069
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

76.91922
68.92085
61.76897
55.37575
49.66266
44.55953
40.00368
35.93917
32.31606
29.08986
26.22095
23.67409
21.418
19.42496
17.6705
16.13307
14.7938
13.63622

Mechanical and Thermal Stress in Test Sample

90
80
70
Shear Stress [MPa]

Adherend 1
Adherend 2
Adhesive
Length[mm]
Line Load [N/mm]
Temperature

60
50
40
30

control

4.572
4.826
5.08
5.334
5.588
5.842
6.096
6.35
6.604
6.858
7.112
7.366
7.62
7.874
8.128
8.382
8.636
8.89
9.144
9.398
9.652
9.906
10.16
10.414
10.668
10.922
11.176
11.43
11.684
11.938
12.192
12.446
12.7
Fmech=

12.64612
11.81134
11.12164
10.56852
10.14522
9.846515
9.668748
9.609734
9.668748
9.846515
10.14522
10.56852
11.12164
11.81134
12.64612
13.63622
14.7938
16.13307
17.6705
19.42496
21.418
23.67409
26.22095
29.08986
32.31606
35.93917
40.00368
44.55953
49.66266
55.37575
61.76897
68.92085
76.91922
350.3578
Fth_1=
Fth_2=

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

12.64612
11.81134
11.12164
10.56852
10.14522
9.846515
9.668748
9.609734
9.668748
9.846515
10.14522
10.56852
11.12164
11.81134
12.64612
13.63622
14.7938
16.13307
17.6705
19.42496
21.418
23.67409
26.22095
29.08986
32.31606
35.93917
40.00368
44.55953
49.66266
55.37575
61.76897
68.92085
76.91922

Shear Stress [MPa]

19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51

30
20
10
0
0

10

Length of Bonded Joint [mm]

0 theoretical max. due to elongation of adherends

0 theoretical max.

15

he first layer due to out-of-plane stresses in the order of the max. shear stresses in the bonding !!!!

Series1
Series2
Series3

Proposed approach for verification of Fatigue

(based on the only available fatigue data foe EA9323 and EA 9432, see 'Materials', approach I) )
(based on ESA PSS-03-210 chapter 8, approach II) )
a) based on test data on similar joint geometry and materials:
I) S(N)average=So,test average/[log(N+100)-1] ; for 10^4 load cycles -> S=So,test/3 , S(10^7)=So,test/6
II) S(N)average=So,test average/(N^0.1)
; for 10^4 load cycles -> S=So,test/4 , S(10^7)=So,test/5
b) based on test data for same adhesive but different joint:
S(N)peak=So,test peak/[log(N+100)-1] or S(N)peak=So,test peak/(N^0.1)

1
10
100
1000
10000
100000
1000000
10000000

1/[log(N+100)-1]
0.99569722
0.960252568
0.768621787
0.489861655
0.332853871
0.249972873
0.199998263
0.166666546

1/(N^0.1)
1
0.79432823
0.63095734
0.50118723
0.39810717
0.31622777
0.25118864
0.19952623

Fatigue of Adhesives
1.2
1

Strength Ratio

0.8
0.6
0.4
0.2
0
1

10

100

1000

10000

Load Cycles

100000 100000010000000

Adhesive

Adherends E-mod
adhesive
EA9321 at RT
alu 1.6mm
2900
EA9321 at RT
CFRP
EA9321 at +80C CFRP
EA9321 at +140CCFRP
EA9321 at -55C alu
EA9321 at RT
3500
EA9321 at +82C
EA9321 at +121C
EA9321 at +149C
EA9321 at +204C
EA9313 at RT
alu
2100
EA9313 at RT
titanium
2100
EA9323 at RT
alu 6.3mm
2870
EA9432 at RT
steel 3mm
4300
EA 9628 at -55C
EA9628 at RT
2400
EA 9628 at +82C
EA9628 at +121C
EA9649 at -55C
EA9649 at RT
EA9649 at +149C
EA9649 at +204C
FM 73 at -55C
FM 73 at RT
2140
FM 73 at +82C
FM 96 at -55C
FM 96 at RT
FM 96 at +82C
FM 96 at +121C
FM 96 at +149C

ult.
G-mod
average
bondline
strain adhesive shear strength length
0.06
1545
27.6
12.7
22.5 to 23.7
22.4
4.9
21
0.025 1346.15
28.8
12.1
7.7
5.1
3.3
0.08
889
29
12.5
0.08
889
22.1
12.5
0.05 1103.85 11.4 to 14.6
80
1653.85
10, 15, 20
0
42
0.055 923.077
41.3
27.5
13
25.2
26.2
18.3
12.1
42.8
0.05 823.077
37
27
24.6
29.9
37.1
33.4
23.6

bondline
fatigue 10^4 endurance 10^7
thickness
peak stress peak stress
0.2 assumed
0.1 to 0.4
0.4
0.4

0.2
0.2
0.1 and 0.3
0.1

20
23.5

Reference
Hysol data sheet
A5 development tests
A5 development tests
A5 development tests
PCA development

GOMOS development
GOMOS development
12 Eng.Fract.Mech.1996
15 Eng.Fract.Mech.1999
catalogue
cured at 120C

catalogue
cured at 180C

catalogue
cured at 120C
catalogue
cured at 175C

Type of
sample
ASTM D 1002

special fatigue
special fatigue

Linear-elastic Analysis of New Joint under Design Loads

E-modulusthickness CTE
G-modulus
70000
1 2.30E-05
100000
1 1.00E-06
0.1
1065

Length[mm]
Line Load [N/mm]
Temperature

20
100 Smean=
100 Kt,mech=

5
5.98349

Smech
29.91745
24.41085
19.91792
16.25211
13.26117
10.82092
8.830009
7.205774
5.880764
4.799957
3.918472
3.199705
2.613808
2.136451
1.747812
1.431753
1.175148
0.967341
0.799705
0.665277
0.558475
0.474864
0.410972
0.364146
0.332441
0.314541
0.309703
0.317726
0.338942
0.374233
0.425065
0.493548
0.582525
0.695693
0.837749
1.014594
1.233571
1.503772
1.836419
2.245325
2.747469

Sthermal
46.06688
37.58659
30.66711
25.0211
20.41412
16.65485
13.58718
11.08373
9.040538
7.372763
6.011149
4.899151
3.990595
3.247751
2.639773
2.141413
1.731977
1.394463
1.114855
0.881542
0.684836
0.516568
0.369751
0.238288
0.116721
0
-0.11672
-0.23829
-0.36975
-0.51657
-0.68484
-0.88154
-1.11485
-1.39446
-1.73198
-2.14141
-2.63977
-3.24775
-3.9906
-4.89915
-6.01115

Xi
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41

0
0.4
0.8
1.2
1.6
2
2.4
2.8
3.2
3.6
4
4.4
4.8
5.2
5.6
6
6.4
6.8
7.2
7.6
8
8.4
8.8
9.2
9.6
10
10.4
10.8
11.2
11.6
12
12.4
12.8
13.2
13.6
14
14.4
14.8
15.2
15.6
16

Scombined
75.98433
61.99744
50.58503
41.27321
33.67529
27.47576
22.41719
18.2895
14.9213
12.17272
9.929621
8.098856
6.604403
5.384203
4.387585
3.573166
2.907125
2.361805
1.91456
1.546819
1.243311
0.991432
0.780723
0.602434
0.449162
0.314541
0.192983
0.079438
-0.03081
-0.14233
-0.25977
-0.38799
-0.53233
-0.69877
-0.89423
-1.12682
-1.4062
-1.74398
-2.15418
-2.65383
-3.26368

E*T

Ce
R
70000 41176.47 0.258643
100000
max.

Shear stress in bonding

100
80
60
40
S[MPa]

Adherend 1
Adherend 2
Adhesive

20
0
-20
-40
-60
0

10

15

Length of bonding

42
43
44
45
46
47
48
49
50
51
control

16.4
16.8
17.2
17.6
18
18.4
18.8
19.2
19.6
20
Fmech=

3.363705
4.11962
5.046606
6.183156
7.576467
9.284396
11.37787
13.94381
17.08878
20.94338
100.3446
Fth_1=
Fth_2=

-7.37276
-9.04054
-11.0837
-13.5872
-16.6548
-20.4141
-25.0211
-30.6671
-37.5866
-46.0669
89.7761
-89.7761

-4.00906
-4.92092
-6.03712
-7.40402
-9.07838
-11.1297
-13.6432
-16.7233
-20.4978
-25.1235
0 theoretical max. due to elongation of adherends
0 theoretical max.

lambda
Fth
Fth0
0.508569 2.20E-03 80.84917
Fthermal=

-90.5882

hear stress in bonding

Smech
Sthermal
Scombined

15

ngth of bonding

20

25

n of adherends