HYBRID METAL–COMPOSITE JOINTS WITH LONGITUDINAL MICRO-ELEMENTS: ANALYTICAL MODELING AND STRENGTH ASSESSMENT

О. О. Вамболь, Ф. М. Гагауз, К. П. Барахов, О. С. Ланець, С. М. Пургіна, О. В. Соловйов

Abstract


This paper addresses the relevant problem of improving the load-bearing capacity and reliability of heterogeneous metal–composite joints widely used in aerospace engineering. It is shown that conventional adhesive joints, despite their technological advantages, exhibit high sensitivity to surface preparation quality and limited ability to effectively transfer interlaminar shear stresses, which reduces their operational reliability.

A novel design and technological solution is proposed, combining the adhesive load transfer mechanism with additional reinforcement in the form of discrete longitudinal connecting elements (micro-fasteners). In contrast to classical approaches, the proposed model accounts for the combined action of the adhesive layer and metallic micro-elements, enabling load redistribution and reducing stress concentrations in the composite part.

An analytical model is developed based on the assumption of a uniform distribution of shear stresses along the joint length and the application of compliance-based approaches. A system of design equations is obtained for determining the main geometric parameters of the joint, including the number of rows of micro-elements, the joint length, the embedment depth into the composite, and the parameters of composite reinforcement.

A numerical evaluation of the joint parameters is performed for a structure made of unidirectional carbon fiber-reinforced polymer bonded with an epoxy adhesive and reinforced with steel micro-elements. The influence of geometric characteristics of the longitudinal connecting elements on the load-bearing capacity is analyzed. It is established that increasing the thickness of the micro-elements leads to a reduction in their number while simultaneously increasing their individual load-bearing capacity, which affects the optimal design parameters.

The obtained results enable engineering design of efficient metal–composite joints considering both structural and technological factors. The proposed approach can be used for further experimental validation as well as for optimization of joint parameters in advanced aerospace structures.


Keywords


polymer composites, composite materials, metal–composite joints, adhesive joints, heterogeneous joints, longitudinal joining elements, joint compliance, aerospace structures

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DOI: https://doi.org/10.32620/oikit.2026.108.12

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