A study of sandwich T -joints and composite lap joints

In this study, new efficient designs for adhesive sandwich T-joint and single-lap joint were proposed and investigated. In the proposed new sandwich T-joint, called U-channel joint, the load transfer path at the web-flange interface was modified to include a U-shaped aluminum channel which provides strong path for load transfer. Experimental results show that the new design has 62% more strength than the conventional circular fillet joint. The new U-channel joint was tested in tension, compression and bending to investigate its characteristics. It is found to have good performance in bending also, even though in compression it performs same as the circular fillet joint. An extensive parametric study was carried out to investigate the effect of parameters like flange skin stiffener, foam density, foam thickness in the web, and aluminum attachments. A fracture mechanics criterion based on the strain energy release rate was used to explain the failure modes, apart from the stress analysis explanation. The failure loads of the joints in compression were predicted using a maximum principal stress failure criterion based on the sandwich beam theory. A new single lap joint with attachments was proposed in the second phase of the research. The design was verified using both aluminum and composite materials. The new design was found to have 59% more strength than the single-lap joint. A parametric study was performed to find out the influence of the angle of attachment, thickness of attachment and the length of attachment. By careful consideration of design parameters, the joint can be optimized. Finally, the failure loads of the single lap joints with and without attachments were predicted using different failure criteria