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 st

Liner-elastic Analysis of Standard Joint under Test Loads; EA9321 acc.to ASTM D 1002
E-modulusthickness CTE G-modulus E*T Ce R lambda Fth Fth0
Adherend 1 70000 1.6 0.00E+00 112000 56000 0.190179 0.436095 0.00E+00 8.004302
Adherend 2 70000 1.6 0.00E+00 112000
Adhesive 0.1 1065 max. Fthermal= 0
Length[mm] 12.7
Line Load [N/mm] 350 Smean= 27.55906
Temperature Kt,mech= 2.791069

1 0 76.91922 0 76.91922
2 0.254 68.92085 0 68.92085

Shear Stress [MPa]

3 0.508 61.76897 0 61.76897 Mechanical and Thermal Stress in Test Sample
4 0.762 55.37575 0 55.37575
5 1.016 49.66266 0 49.66266 90
6 1.27 44.55953 0 44.55953
7 1.524 40.00368 0 40.00368
80
8 1.778 35.93917 0 35.93917
9 2.032 32.31606 0 32.31606
10 2.286 29.08986 0 29.08986 70
11 2.54 26.22095 0 26.22095
12 2.794 23.67409 0 23.67409 60
13 3.048 21.418 0 21.418
14 3.302 19.42496 0 19.42496 50 Column
15 3.556 17.6705 0 17.6705 C
16 3.81 16.13307 0 16.13307 40 Column
D
30

20

10
 60

50 Column
C
40 Column
17 4.064 14.7938 0 14.7938 D
18 4.318 13.63622 0 13.63622 30
19 4.572 12.64612 0 12.64612
20 4.826 11.81134 0 11.81134
20
21 5.08 11.12164 0 11.12164
22 5.334 10.56852 0 10.56852
23 5.588 10.14522 0 10.14522 10
24 5.842 9.846515 0 9.846515
25 6.096 9.668748 0 9.668748 0
26 6.35 9.609734 0 9.609734 0 2 4 6 8 10 12 14
27 6.604 9.668748 0 9.668748
Length of Bonded Joint [mm]
28 6.858 9.846515 0 9.846515
29 7.112 10.14522 0 10.14522
30 7.366 10.56852 0 10.56852
31 7.62 11.12164 0 11.12164
32 7.874 11.81134 0 11.81134
33 8.128 12.64612 0 12.64612
34 8.382 13.63622 0 13.63622
35 8.636 14.7938 0 14.7938
36 8.89 16.13307 0 16.13307
37 9.144 17.6705 0 17.6705
38 9.398 19.42496 0 19.42496
39 9.652 21.418 0 21.418
40 9.906 23.67409 0 23.67409
41 10.16 26.22095 0 26.22095
42 10.414 29.08986 0 29.08986
43 10.668 32.31606 0 32.31606
44 10.922 35.93917 0 35.93917
45 11.176 40.00368 0 40.00368
46 11.43 44.55953 0 44.55953
47 11.684 49.66266 0 49.66266
48 11.938 55.37575 0 55.37575
49 12.192 61.76897 0 61.76897
50 12.446 68.92085 0 68.92085
51 12.7 76.91922 0 76.91922
control Fmech= 350.3578
Fth_1= 0 0 theoretical max. due to elongation of adherends
Fth_2= 0 0 theoretical max.
he first layer due to out-of-plane stresses in the order of the max. shear stresses in the bonding !!!!

ample

Column
C
Column
D
 Column
C
Column
D

14
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)

N 1/[log(N+100)-1] 1/(N^0.1)
1 0.99569722014 1 Fatigue of Adhesives
Strength Ratio
10 0.96025256779 0.794328235
100 0.76862178684 0.630957344
1000 0.48986165536 0.501187234 1.2
10000 0.33285387134 0.398107171
100000 0.2499728731 0.316227766 1
1000000 0.19999826292 0.251188643
10000000 0.16666654603 0.199526231 0.8

0.6

0.4

0.2

0
1 10 100 1000 10000 100000 1000000 10000000
Load Cycles
Adhesive Adherends E-mod ult. G-mod average bondline bondline fatigue 10^4 endurance 10^7 Reference
adhesive strain adhesive shear strength length thickness peak stress peak stress
EA9321 at RT alu 1.6mm 2900 0.06 1545 27.6 12.7 0.2 assumed Hysol data sheet
EA9321 at RT CFRP 22.5 to 23.7 0.1 to 0.4 A5 development tests
EA9321 at +80°C CFRP 22.4 0.4 A5 development tests
EA9321 at +140°CCFRP 4.9 0.4 A5 development tests
EA9321 at -55°C alu 21 PCA development
EA9321 at RT 3500 0.025 1346.154 28.8
EA9321 at +82°C 12.1
EA9321 at +121°C 7.7
EA9321 at +149°C 5.1
EA9321 at +204°C 3.3
EA9313 at RT alu 2100 0.08 889 29 12.5 0.2 GOMOS development
EA9313 at RT titanium 2100 0.08 889 22.1 12.5 0.2 GOMOS development
EA9323 at RT alu 6.3mm 2870 0.05 1103.846 11.4 to 14.6 80 0.1 and 0.3 20 12 Eng.Fract.Mech.1996
EA9432 at RT steel 3mm 4300 1653.846 10, 15, 20 0.1 23.5 15 Eng.Fract.Mech.1999
EA 9628 at -55°C 0 42 catalogue
EA9628 at RT 2400 0.055 923.0769 41.3 cured at 120°C
EA 9628 at +82°C 27.5
EA9628 at +121°C 13
EA9649 at -55°C 25.2 catalogue
EA9649 at RT 26.2 cured at 180°C
EA9649 at +149°C 18.3
EA9649 at +204°C 12.1
FM 73 at -55°C 42.8 catalogue
FM 73 at RT 2140 0.05 823.0769 37 cured at 120°C
FM 73 at +82°C 27
FM 96 at -55°C 24.6 catalogue
FM 96 at RT 29.9 cured at 175°C
FM 96 at +82°C 37.1
FM 96 at +121°C 33.4
FM 96 at +149°C 23.6
Type of
sample
ASTM D 1002

special fatigue
special fatigue
Linear-elastic Analysis of New Joint under Design Loads
E-modulusthickness CTE G-modulus E*T Ce R
Adherend 1 70000 1 2.30E-05 70000 41176.47 0.258643
Adherend 2 100000 1 1.00E-06 100000
Adhesive 0.1 1065 max.

Length[mm] 20
Line Load [N/mm 100 Smean= 5
Temperature 100 Kt,mech= 5.98349

Xi Smech Sthermal Scombined

1 0 29.91745 46.06688 75.98433
2 0.4 24.41085 37.58659 61.99744
Shear stress in bonding
3 0.8 19.91792 30.66711 50.58503
4 1.2 16.25211 25.0211 41.27321 100
5 1.6 13.26117 20.41412 33.67529
6 2 10.82092 16.65485 27.47576 80
7 2.4 8.830009 13.58718 22.41719

S[MPa]
8 2.8 7.205774 11.08373 18.2895 60
9 3.2 5.880764 9.040538 14.9213
10 3.6 4.799957 7.372763 12.17272 40
11 4 3.918472 6.011149 9.929621
12 4.4 3.199705 4.899151 8.098856 20
13 4.8 2.613808 3.990595 6.604403
14 5.2 2.136451 3.247751 5.384203 0
15 5.6 1.747812 2.639773 4.387585
16 6 1.431753 2.141413 3.573166 -20
17 6.4 1.175148 1.731977 2.907125
-40
18 6.8 0.967341 1.394463 2.361805
19 7.2 0.799705 1.114855 1.91456
-60
20 7.6 0.665277 0.881542 1.546819
0 5 10 15 20
21 8 0.558475 0.684836 1.243311
22 8.4 0.474864 0.516568 0.991432 Length of bonding
23 8.8 0.410972 0.369751 0.780723
24 9.2 0.364146 0.238288 0.602434
25 9.6 0.332441 0.116721 0.449162
26 10 0.314541 0 0.314541
27 10.4 0.309703 -0.116721 0.192983
28 10.8 0.317726 -0.238288 0.079438
29 11.2 0.338942 -0.369751 -0.030809
30 11.6 0.374233 -0.516568 -0.142335
31 12 0.425065 -0.684836 -0.259771
32 12.4 0.493548 -0.881542 -0.387994
33 12.8 0.582525 -1.114855 -0.53233
34 13.2 0.695693 -1.394463 -0.69877
35 13.6 0.837749 -1.731977 -0.894228
36 14 1.014594 -2.141413 -1.126819
37 14.4 1.233571 -2.639773 -1.406202
38 14.8 1.503772 -3.247751 -1.743979
39 15.2 1.836419 -3.990595 -2.154176
 40 15.6 2.245325 -4.899151 -2.653826
41 16 2.747469 -6.011149 -3.263679
42 16.4 3.363705 -7.372763 -4.009059
43 16.8 4.11962 -9.040538 -4.920918
44 17.2 5.046606 -11.08373 -6.037121
45 17.6 6.183156 -13.58718 -7.404021
46 18 7.576467 -16.65485 -9.078379
47 18.4 9.284396 -20.41412 -11.12972
48 18.8 11.37787 -25.0211 -13.64324
49 19.2 13.94381 -30.66711 -16.7233
50 19.6 17.08878 -37.58659 -20.4978
51 20 20.94338 -46.06688 -25.1235
control Fmech= 100.3446
Fth_1= 89.7761 0 theoretical max. due to elongation of adherends
Fth_2= -89.7761 0 theoretical max.
 lambda Fth Fth0
0.508569 2.20E-03 80.84917

Fthermal= -90.58824

hear stress in bonding

Smech
Sthermal
Scombined

10 15 20 25
ength of bonding
on of adherends