Experimental and numerical analysis of geometry on joint strength in GFRP-aluminum alloy adhesive joints

Enhancing the bonding strength between composites and metals is one of the urgent challenges that needs to be addressed. One of the methods to improve the strength of adhesive joints is to change the geometry of the joints. In this paper, four different types of aluminum alloy sleeves were developed by designing grooves with varying angles and shapes. Glass fiber reinforced polymer rods were adhesively bonded to these sleeves, resulting in the preparation of five different types of adhesive joints, including a conventional structure. The mechanical performance and failure mechanisms of these joints were analyzed experimentally and numerically. The results indicate that, compared to conventional adhesive joints, the load-bearing capacity of the four designed adhesive joints has been significantly improved, with a maximum increase of 49.6% and a minimum increase of 35.6%. The axial angle of the groove structures designed within the joint is a factor that influences the ultimate load capacity of the joint. Furthermore, the shear stress in the adhesive layer is identified as the primary cause of adhesive layer failure. The designed mechanical interlocking structures can not only increase the interfacial bonding force between the adhesive layer and the substrate but also delay the complete failure of the adhesive layer, thereby improving the load-bearing strength of the joint. This work is expected to provide new insights for the design of composite and metal joints.