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Additive Manufacturing for Bonded Composite Joints



Interface design is very critical for bonded joints in fiber reinforced polymer composites (FRCPs) and a smart designing technique should be developed to minimize the damage and failure incurred by weak bond interfaces. It is hypothesized that improvement in strength and toughness can be achieved by imparting structural texture at the adhesively bonded joint interfaces. Towards that, a novel technology using additive manufacturing at the bond interfaces has been explored in this paper. Various computational models were developed to simulate stress distribution along the overlap region of single lap shear joints. The models that performed best were chosen for manufacturing and testing. Pure adhesive joints were manufactured first, followed by two 3D-printed adhesive (3D-PA) joints. Peak loads, shear stresses, and failure types were compared between each design. It was observed from this study that pure adhesive joints failed predominantly adhesively, resulting in low peak loads and shear strength (average 1502.06 KPa). According to 3D-PA results, model 1 and 2 registered an average shear strength of 6716.45 KPa and 10050.24 KPa, respectively exhibiting mainly cohesive type failure. Overall, the experimental results corroborated the expected behavior from the computational predictions, suggesting a major improvement imparted by the additively manufactured bonded joint reinforcements.

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