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This paper presents the results of experimental research and numerical calculations regarding the static strength and fatigue life of hybrid joints. In the experiments, specimens built as single-lap adhesive–mechanical joints (hybrid joints) were tested. In a two-stage process of the failure of the hybrid joints, the adhesive joint was damaged first. Therefore, it was assumed that the assembly of fasteners closer to the edge of the overlap (beyond the ranges recommended for mechanical joints) limits the negative impact of the peeling phenomenon on the strength and performance properties of hybrid joints. The specimens used in the experiments were prepared from composite elements (i.e., carbon fiber-reinforced polymer (CFRP)), as well as from the aluminum alloy 2024T4. Because the detection of fatigue damage in composite materials is a complex problem, computed tomography was used to evaluate the degradation of the composite material. Experimental and numerical comparative analyses of the static strength and fatigue life of hybrid joints with adhesive and mechanical joints confirmed the assumptions made.

One of the most relevant geometrical factors defining an adhesive joint is the thickness of the adhesive layer. The influence of the adhesive layer thickness on the joint strength has not been precisely understood so far. This article presents simplified analytical formulas for adhesive joint strength and adhesive joint coefficient for different joint loading, assuming, inter alia: linear-elastic strain of adhesive layer, elastic strain of adherends and only one kind of stress in adhesive. On the basis of the presented adhesive joint coefficient, the butt joint was selected for the tests of the influence of adhesive thickness on the adhesive failure stress. The tests showed clearly that with an increase in the thickness of the tested adhesive layers (up to about 0.17 mm), the value of their failure stress decreased quasi linearly. Furthermore, some adhesive joints (inter alia subjected to shearing) may display the optimum value of the thickness of the adhesive layer in terms of the strength of the joint. Thus, the aim of this work was to explain the phenomenon of optimal adhesive layer thickness in some types of adhesive joints. The verifying test was conducted with use of single simple lap joints. Finally, with the use of the FE method, the authors were able to obtain stresses in the adhesive layers of lap joints for loads that destroyed that joints in the experiment, and the FEM-calculated failure stresses for lap joints were compared with the adhesive failure stresses determined experimentally using the butt specimens. Numerical calculations were conducted with the use of the continuum mechanics approach (stress-based), and the non-linear behavior of the adhesive and plastic strain of the adherends was taken into account.

Abstract. The subject of the present paper is the modeling of aircraft structure fatigue processes which endanger flight safety. It is assumed that the simple course of the process of aircraft structure elements fatigue encompasses the following stages: initiation of cracks, crack development to the limit value, destruction of the element of structure . These stages can be taken as random incidents or random processes. The paper provides a description of the two initial stages as random processes. The relations obtained allow to define the reliability of the structure element and to evaluate the damage hazard in given time period.Key words: fatigue crack, stress intensity factor, damage hazard, fatigue life.Streszczenie. Referat dotyczy modelowania procesów zmęczenia konstrukcji statku powietrznego, które zagrażają bezpieczeństwu lotów. Przyjmuje się, że prosty przebieg procesu zmęczenia elementów konstrukcji statku powietrznego obejmuje etapy: inicjacji pęknięć, wzrostu pęknięcia do wartości granicznej, zniszczenia elementu konstrukcji. Etapy te można traktować jako zdarzenia losowe lub procesy losowe. Referat obejmuje opis pierwszych dwóch etapów jako procesów losowych. Otrzymane zależności pozwalają określić niezawodność elementu konstrukcji i oszacować ryzyko uszkodzenia w przyjętym przedziale czasu.Słowa kluczowe: pękanie zmęczeniowe, współczynnik intensywności naprężeń, ryzyko uszkodzenia, trwałość zmęczeniowa.

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