Qiang Yu (Post-Doctoral Researcher , Department of Civil and Environmental

Engineering , Northwestern University)

Zdenek P. Bazant (Professor Department of Civil and Materials Science ,
Northwestern University )
John Bayldon ( Post-Doctoral Researcher Department of Engineering, University of
Cambridge)
Jia-Liang Le ( Graduate Research Assistant , Department of Civil and Environmental
Engineering , Northwestern University)

ASME
Vol. 77 / 011011(1-8), 011012(1-7)
Scaling of strength of Metal-Composite
Joints Part 1-2
Rohit Singh Karakoti
M.Tech(10CE65R19)
Structural Engineering Division
Department of Civil Engineering
IIT Kharagpur
Presentation Overview
Background
Introduction
Experimental Investigation
Interface Fracture Analysis
General size law
Numerical Evaluation of Model
Parameters
Interpretation of Experimental Test
Conclusion
Reference

Background
In the past four decades, extensive analytical studies
have been devoted to the effect of structure size on the
strength of structures made of quasibrittle materials .
For a homogeneous body Williams showed the
dependence of the stress singularity exponent on the
angle of a corner.
Size effect law is derved in the recent study of
symmetrical loaded V notches corners in homogenous
materials of various corner angles.
In the derived law only the real part of singularity is
important.
Background
In previous studies theoretical size effect law
represent a smooth transition from quasiplastic
behavior in the small-size limit to brittle linear
elastic fracture mechanics behavior in the large-
size limit.

This asymptotic matching approach for V-notches
in homogeneous body has been shown to lead to
good agreement with experiments.
Introduction
Knowledge of the size effect on the strength of hybrid bi-
material joints of steel and fiber composites is important
for new designs of large lightweight ships, large fuel-
efficient aircrafts, and light weight crashworthy
automobiles.
In the present study the size effect in the joints is
energetic ( non statistical ) and caused by the presence of
material fracture energy or material characteristic
length in material failure criteria.



f
G
o
l
Introduction
The singularity exponent of stress field at the tip
of the crack is complex number.
For the finite corner angle the real part of the
corner tip stress singularity is greater than -1/2 so
energy balance is not satisfied.
And to satisfy the energy release rate a finite FPZ
is approximated near the corner.



Introduction..
The energy release rate is found to be related
with real part of the stress singularity the same is
seen in the homogeneous material.
The general size effect derived for the
homogeneous material then is used for the hybrid
joint.


Experimental Investigation
Three series of scaled geometrically similar
specimens of symmetric double-lap joints are
manufactured.

In the first two test series laminate were
manufactured and tested at Northwestern University.

In third series with a slightly different geometry was
manufactured and tested at the University of
Michigan to explore the size effect for a different type
of laminate
The specimens of series I
and II were loaded in
tension through chains at
both ends to ensure that
the tension resultant is
centric.

The size ratios have been
selected as 1:4:12.

In series I smallest
specimen was found to
fail by tensile fracture .

The width of the
specimen in the third
dimension is constant
b=20mm.


The specimens of series III
were fixed at both ends
against rotation and loaded
at both ends by wedge
grips and the size ratio is
1:3:4:12.

The optimal selection of
dimensions are determined
by finite element simulation
and it is ensured that the
steel block would still be in
the elastic range when the
hybrid joint fails.

Experimental Investigation.
Properties of Composites
Metallic part is made of 1018 cold rolled steel having
elastic modulus E=200 G Pa and Poissons ratio
=0.3.

Composites of the hybrid joint of I and II series is
fiberglass-epoxy laminates G-10/FR4 Epoxy Grade.

In-plane and through-thickness material properties of
G-10/FR4 Garolite are obtained by testing as
E
11
=30.0 GPa, v
13
=0.17, E
22
=9.5 GPa, v
21
=0.20, and
G
12
=3.0 GPa.
v
Experimental Investigation.

In series III composites are made using Newport
NCT301 carbon laminates properties for the uniaxial
composites are: E
11
=125.5 GPa ,E
22
=9.0 Gpa and
G
12
=5.6 Pa, = = 0.304.

The adhesive used is NB1101 epoxy film adhesive.




12
v
13
v
Load-displacement deformation
curves
Interface Fracture Analysis
In the lap joint both loading
and structure is symmetric.

There are two critical bi-
material corners where
singularity and stress
concentration is relevant.

To identify the critical corner
from which the crack
propagates, the stress
singularity exponents is
calculated.

Interface Fracture Analysis
For a plain strain problem governing equation for stress
function is.


The solution is in the form of

Hence the dispacements,boundary traction , stress field
in each layer of material can be repented by two function
and
where and is the root of
characteristic equation




0 ) 2 (
4
4
11
2 2
4
66 12
4
4
22
=
c
c
+
c c
c
+ +
c
c
y
f
S
y x
f
S S
x
f
S
) ( y x f f + =
) (
1 1
z f
) (
2 2
z f
y x z
j i
+ =
j

0 ) 2 (
22
2
66 12
4
11
= + + + S S S S
Interface Fracture Analysis.
Near the crack tip displacement field can be assumed
as separable hence complex potential is expressed as.


Thus by imposing the boundary condition. The system
of linear equations , with matrix form are forulated.


The displacement singularity is solved for the condition
det(K)=0.The singularity is calculated numerically for
which the condition number of matrix K become very
large.



) 2 , 1 .....( ) sin (cos ) ( = + = = k r z z f
k k k k k k
o o o
0 u | |
0 ) ( = v o K
Interface Fracture Analysis.
g
g
Interface Fracture Analysis.
The size effect law is satisfied for large sizes in linear
elastic fracture mechanics and stress field corresponding
to strongest singularity is relevant.
For strongest singularity stress field is
represented as .

The energy balance seems impossible in this condition.
The approximation is done by forming a finite size FPZ
whose effect on elastic field is approximated by the
formation of equivalent crack whose length is
proportional to length of FPZ and is taken as .
Therefore at maximum load elastic field of stress is close to
interface crack.




q k i =
k
ij
i
ij
r Hr )] ( Re[ u o o
q
=
f
c
FPZ
l
2
FPZ
l
Interface Fracture Analysis.






It has been shown that the interface crack must have the
form.

The stress intensity factor of the interface crack tip K will
depend on the stress field whose magnitude is
characterized by the stress intensity factor H of the
corner.
'
2 1 q i
crack
+ =
Interface Fracture Analysis.
The two stress intensity factors are related as


Within the frame work of linear elastic fracture mechanics,
a crack can propagate once reaches a certain critical value
of fracture energy and this also represent the condition of
maximum load P.


Hence the nominal strength( ) can be related as



k
k
o D c EG g
f f N
5 . 0
1

=
,
q q i
f
k
f
i
f
c Hc Kc
5 . 0
'
+
=
bD P
max
General size effect Law






The entire singular stress field is governed solely by one
real stress singularity .
In bi-material real part of the strongest singularity exponent
matters for the energy release rate at the large size limit.

General size effect Law

The equation of similar type can be used to approximate
the general size effect law..


Parameters and are obtained by the model
on the basis of available size effect data.





) (
0 0
) / 1 (
| k
|
o o D D
N
+ =
| 0
D
) (| o
o
Numerical Evaluation of model
parameter.

is obtained by finite element analysis of model and
thus can be obtained by equation.



The singular stress zone is also obtained by finite
element analysis at the right and left corner.

By matching the stress field the stress singularity in left
corner is obtained as -.219.






f
G
f
c
5 .
) (
) (
) (
+
=
k k
|
|
|
| o
f
f
o
c g
EG
D
Numerical Evaluation of model
parameter.
Interpretation of experimental results
Interpretation of experimental results
For a fourfold size increase, the nominal strength
reduction is significant 52% in series II and 40% in
series III.

The test data fitted by size effect equation.


) (
0 0
) / 1 (
| k
|
o o D D
N
+ =
Interpretation of experimental results


Interpretation of experimental
results..


Conclusion

The present study explain well that the strength of
metal-composite hybrid joints cannot be calculated
with failure criteria expressed solely in terms of
stress and strain as done in elastic models.

The fracture mechanics models in which the failure
criterion involves some type of energy or material
length, must be used otherwise the strength of hybrid
joint would be dangerously over estimated.

Reference

Bazant,Z.P..1993 STABILITY OF STRUCTURES Elastic,
Inelastic, Fracture, and Damage Theories DOVER
PUBLICATIONS, INC. Mineola, New York
Baant, Z. P., and Yu, Q., 2006, Size Effect on Strength of
Quasibrittle Structures With Reentrant Corners Symmetrically
Loaded in Tension, J. Eng. Mech., 13211, pp. 11681176.
Martin H Sadd 2009Elasticity Application,Theory and Numerics
2
nd
ed Elsevier Inc.london.
Prashant Kumar 1999 Element of Fracture Mechanics First
edition Wheeler Publication.
Suo, Z., 1990, Singularities, Interfaces and Cracks in Dissimilar
Anisotropic Media, Proc. R. Soc. London, Ser. A, 427, pp. 331
358.


Thank You