The present paper
provides a solution to enhance the reliability
of bonding. The effect of the nonwoven carbon tissue (NWCT) composite
adhesive layer on the bonding strength and reliability of aluminum
alloy of single lap joints (SLJ) was investigated by embedding NWCT
into the epoxy adhesive layer. The bonding strength, Weibull distribution,
metallography of cross section, and fracture surface morphology of
NWCT specimens were investigated. The results showed that the average
bonding strength and Weibull characteristic strength (WCS) of NWCT-reinforced
specimen were 16.78 and 17.17 MPa, which increased by 70.2 and 66.7%,
respectively, compared with the neat specimen, and the Weibull modulus
increased from 11.46 to 22.83, which indicated that NWCT specimens
had higher bonding reliability. The mechanism of microcrack formation
was obtained by analyzing the cross section of specimen loaded 95%
WCS without macroscopic damage. The metallographic section showed
that the microcrack of the neat specimen originated from the adhesive–aluminum
interface, while the microcracks of the NWCT specimen originated from
the interface between short carbon fibers (SCF) and adhesive. Typical
failure modes were gained from visual observation and SEM. The failure
mode of the neat specimen included more Al–adhesive interface
failure, while the NWCT specimen included more internal failure of
adhesive–SCFs with the fracture, pullout, peeling, and slippage
of SCFs improving the toughness and bonding strength of the adhesive
layer. The bridging effect of SCFs in the adhesive layer reinforced
by NWCT can even the load and release the stress to improve the bonding
reliability.