Single-lap adhesive joints: CZM-based correlation with ASTM D1002 test results

Composite materials are increasingly used in advanced engineering applications for their exceptional strength-to-weight ratio, high stiffness, and tailored performance. Aerospace, automotive, marine, and energy sectors adopt fibre-reinforced polymer (FRP) composites to reduce mass and improve efficiency. However, large or complex components require joining, and joint performance is often critical for overall reliability. Among joining techniques, adhesive bonding offers lightweight advantages, uniform stress distribution, and improved fatigue behaviour compared to mechanical fastening, though challenges remain such as environmental sensitivity and complex failure mechanisms. Designing reliable adhesive joints demands deep understanding of materials, geometry, and loading. The ASTM D1002 single-lap shear test is the standard for assessing shear strength of structural adhesives under tensile loading, though shear and peel interactions complicate interpretation. Finite Element Modelling (FEM), particularly Cohesive Zone Models (CZM), complements testing by simulating crack initiation and propagation through traction–separation laws and fracture energy criteria, effectively reproducing adhesive failure. This thesis, developed in collaboration with Bucci Composites, addresses the adhesive bonding of composite wheels where aluminium inserts are joined to carbon fibre rims. The work aims to experimentally characterise hybrid aluminium–composite joints via ASTM D1002 tests, develop validated CZM-based FEM models, and compare experimental and numerical results to establish a methodology for adhesive joint characterization and support Bucci’s products.