Stress concentrations in a three dimensional hybrid

composite-steel joint model

S. Narasimhan, R.A. Shenoi
*
, J.I.R. Blake and S.W. Boyd

Fluid Structure Interactions Research Group
School of Engineering Sciences
University of Southampton
Southampton SO17 1BJ, UK
Fax: (44)-2380-59-3299
Phone: (44)-2380-59-2356
r.a.shenoi@ship.soton.ac.uk

ABSTRACT

This paper is concerned with the critical stress concentrations that occur in an
adhesively bonded hybrid metal-composite joint. The hybrid joint considered in the
study is based on the design for hanger to weather deck connections currently in
service in the French navy on the La Fayette class frigates. The joint consists of the
materials like E-glass woven roving mat, vinylester resin, balsa wood core and 6mm
thick mild steel. A three dimensional finite element analysis is performed for this
hybrid joint given that its width is considerable. Interesting normal and shear stress
patterns are seen across the width of the joint thus providing an insight to identify the
location(s) of high stress concentration in the hybrid joint. It is highlighted that a two
dimensional analysis will not be adequate where edge-effects are prominent under the
in-plane static load.

Keywords: Hybrid composite-steel joints, three dimensional FE model, Stress
concentrations






*
Corresponding Author
INTRODUCTION


The application of hybrid composite-metal joint structures has been gaining
momentum over the past few years in various disciplines of aerospace, land transport
and in marine industry [1-5]. The prime objective in using the hybrid structures is to
reduce weight. The hybrid joint considered here is based on the design for hanger to
weather deck connections currently in service in the French navy on the La Fayette
class frigates. The joint is manufactured from a 3x1 twill weave 780g/m
2
E-glass
woven roving (Chomarat 800S4), vinylester (Dow Derakane 411-C50), 150kg/m
3

Balsa wood core (Baltek AL600-10 Contourcore) and 6mm thick mild steel (D55).
The joint specimen was prepared by vacuum resin infusion moulding process where 8
plies of glass reinforcement is laid over the top and bottom side of steel and balsa
wood. This joint is asymmetric in geometry with balsa tapering on one side and flat
on other side, as the requirement for a flush outer surface in superstructure to deck
connections (figure 1).

The objective of the work is to identify the initiation and propagation of the crack that
leads to failure of the hybrid joint under a compressive loading. Although various
experimental and modelling studies on hybrid joints have been undertaken earlier [2-
5], not much information is available on stress variations across the width of the
hybrid joint. Hence it is felt that a three dimensional finite element (FE) analysis of
such hybrid joint can be very useful in locating the critical stress concentration.

FINITE ELEMENT MODELLING AND ANALYSIS

Three dimensional analysis is done using a nonlinear FE program code developed
using a 20-noded isoparametric finite element [6]. Initial analysis have shown that the
joint would produce a lateral deflection due to the eccentricity in the compressive
load. To prevent this, a system of anti-bending guides were positioned at steel/balsa
interface. The geometry and FE model of the hybrid joint is shown in figure 1. A three
dimensional FE mesh for the hybrid joint is generated using a 20-noded three
dimensional isoparametric element with 3x3x3 Gaussian integration scheme. The FE
model had 548 elements and 3347 nodes. Load and boundary conditions were applied
similar to that of experimental set up including the presence of anti-bending guides to
arrest lateral deflection. An uniform compressive load of 120kN which is found to be
the ultimate load carrying capacity of the joint from the experiments [5] was applied
in 12 increments of 10kN each. Figure 2 shows good correlation between
experimental and numerical stiffness in the linear region thus validating the FE
program developed with 20-noded 3D finite element.

Considering the asymmetrical geometry and the presence of three different materials
in the hybrid joint, there are different interface layers to observe the stress
distributions. Of those layers, the critical stress values are seen along the FRP/Core
and FRP/Steel interface layer along the flat side of the joint and at the vertical plane
where the tapering ends. Normal and shear stress distributions shown in figure 3 and 4
were obtained from such interface layers. These stress contours show that the stress
values are not uniform across the width of the joint either along the length or through
the thickness of the hybrid joint. Normal stress increases steeply towards the mid-line
of the joint from the edges at the critical location of FRP-Core-Steel interface layer. It
is to be observed that although the maximum stress occurs along the mid-line the
stress variation at the beginning (X=60.0mm) across the width shows maximum stress
value at the ends rather at the mid-line. Shear stress plot in figure 3 also shows a
similar behaviour of maximum stress at the edges than at the mid-line even though the
stress magnitude difference is not much. This non-uniform stress variation across the
width indicates a typical three dimensional behaviour that is seen in typical single lap
joint which is termed as anticlastic effect [6]. This arises due to different elongation
between the adherends owing to their differing material properties and the bending of
the hybrid joint because of asymmetry in shape. Figure 4 shows normal stress
variation across the width along the vertical plane at FRP-Core-Steel interface layer.
Here also the stress variation is so significant and highlights the three dimensional
behaviour in third direction as well. Stress variation in the lateral direction for the
hybrid joints had not been reported in earlier works and from these plots, it can be
very well stated that three dimensional FE analysis of joints with considerable width
will be informative in identifying the occurrence of stress concentration. Given that
stresses are maximum along mid-line at one place and maximum at edges at some
other sections, a structural joint of this configuration should be analysed in a three
dimensional domain rather opting for a plane stress/strain model.
From the maximum value of the normal and shear stress components (26 and 82Mpa
respectively), it is more likely that shear component stress is dominant in initiating the
failure and occurs at the FRP-Core-Steel interface. However a steep normal steep
gradient plays a significant role in rapid up the failure initiation and further
propagation as shown in figure 5 for the test specimen.

CONCLUSION

A three dimensional FE model of a hybrid composite-steel joint is generated and
analysed for static compression loading. Numerical and experimental stiffness were to
be found in good correlation up to linear region. Normal and shear stress variations
showed significant three dimensional behaviour and the relevance of analyzing the
joints of such configurations in a three dimensional domain instead of a 2D plane
stress/strain analysis has been demonstrated. Failure of the joint initiates at FRP-Core-
Steel interface layers on the flat side of the joint specimen and propagates further on
either directions.

REFERENCES

[1] Mouritz AP, Gellert E, Burchill P, Challis K. Review of advanced composite
structures for naval ships and submarines. Composite structures 2001;53:21-41.
[2] Wright PNH, Wu Y, Gibson AG. Fibre reinforced composite-steel connections for
transverse ship bulkheads. Plastics, Rubeer and Composites 2000;29(10):549-557.
[3] Clifford SM, Manger CIC, Clyne TW. Characterisation of a glass-fibre reinforced
vinylester to steel joint for use between a naval GRP superstructure and a steel hull.
Composite Structures 2002;57:59-66.
[4] Cao J, Grenestedt JL. Test of a redesigned glass-fibre reinforced vinylester to steel
for use between a naval GRP superstructure and a steel hull. Composite Strctures
2003;60:439-445.
[5] Boyd SW, Blake JIR, Shenoi RA, Mawella J. Fatigue life characterization of
hybrid composite-steel joints. Proceedings of the International Conference on
Advanced Marine Materials: Technology & Application, London, 9-10 October 2003.
p. 79-87.
[6] Narasimhan S, Shenoi RA, Jeong HK. Three-dimensional stresses in adhesively
bonded lap joints with non-identical adherends. Part L: Journal of Materials: Design
and Applications, Proc. of IMechE 2004;218:283-298.



Figure 1: Geometry and FE model of the hybrid joint
0
20
40
60
80
100
120
140
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
U_xx Displacement (mm)
A
p
p
l
i
e
d

l
o
a
d

(
k
N
)
Expt. result
FE result
Figure 2: Load-Deflection curve


Figure 3: 3D Normal and Shear stress contours along FRP/Balsa and FRP/Steel
interface layer

Figure 4: 3D Normal stress contour along the vertical plane along the FRP/Balsa/Steel
interface layer



Figure 5: Failure initiation and propagation in the hybrid joint under compressive load