Investigation on static and fatigue performance of CFRP/Al-alloy interference bolted joint considering the influence of hole-axis error

IF 5.7 2区工程技术 Q1 ENGINEERING, MECHANICAL Engineering Failure Analysis Pub Date : 2025-03-10 DOI:10.1016/j.engfailanal.2025.109516

Caoyang Wang , Hui Cheng , Wenlong Hu , Yuan Li , Kaifu Zhang , Yi Cheng

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Abstract

Hole-axis error is one of the normal manufacturing errors during aircraft assembly due to non-uniform deformation caused by drilling, assembly force, and post-assembly positioning. This paper investigated the influence of hole-axis error on the static and fatigue performance of CFRP/Al-alloy bolted joints. Experimental investigations were carried out to evaluate the impact of hole-axis error (0.00 mm, 0.05 mm, 0.10 mm, and 0.15 mm) on static and fatigue performance of CFRP/Al-alloy interference bolted joints. The variation of hole-axis error within a certain range has a slight influence on the ultimate tensile strength of the joint. At the same time, the fatigue life increases at first and then decreases with the increase in the value of the hole-axis error. The hole-axis error introduces a pre-loading state of the bolted joint, which makes the material damaged in advance and decreases the structure stiffness. A scanning electron microscope (SEM) was used to observe the damage of holes. A modified fatigue life model was proposed to predict the fatigue life of CFRP/Al-alloy bolted joints with different hole-axis errors. A rational threshold for hole-axis error can be established, which is less than 0.15 mm (3 %). The results of this paper can provide corresponding guidance for the tolerance design of bolted joints with hole-axis error.

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考虑孔轴误差影响的CFRP/铝合金干涉螺栓连接静力及疲劳性能研究

孔轴误差是飞机装配过程中常见的制造误差之一，主要是由于钻孔、装配力和装配后定位引起的不均匀变形。研究了孔轴误差对CFRP/铝合金螺栓连接静力性能和疲劳性能的影响。通过试验研究了孔轴误差（0.00 mm、0.05 mm、0.10 mm和0.15 mm）对CFRP/铝合金干涉螺栓连接静力和疲劳性能的影响。孔轴误差在一定范围内的变化对接头的极限抗拉强度影响不大。同时，随着孔轴误差值的增大，疲劳寿命先增大后减小。孔轴误差导致螺栓连接进入预加载状态，使材料提前损坏，降低结构刚度。利用扫描电镜（SEM）观察了孔洞的损伤情况。提出了一种修正的疲劳寿命模型，用于预测不同孔轴误差的CFRP/铝合金螺栓连接的疲劳寿命。可以建立合理的孔轴误差阈值，其误差小于0.15 mm（3%）。研究结果可为具有孔轴误差的螺栓连接公差设计提供相应的指导。

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来源期刊

Engineering Failure Analysis 工程技术-材料科学：表征与测试

CiteScore

7.70

自引率

20.00%

发文量

956

审稿时长

47 days

期刊介绍： Engineering Failure Analysis publishes research papers describing the analysis of engineering failures and related studies. Papers relating to the structure, properties and behaviour of engineering materials are encouraged, particularly those which also involve the detailed application of materials parameters to problems in engineering structures, components and design. In addition to the area of materials engineering, the interacting fields of mechanical, manufacturing, aeronautical, civil, chemical, corrosion and design engineering are considered relevant. Activity should be directed at analysing engineering failures and carrying out research to help reduce the incidences of failures and to extend the operating horizons of engineering materials. Emphasis is placed on the mechanical properties of materials and their behaviour when influenced by structure, process and environment. Metallic, polymeric, ceramic and natural materials are all included and the application of these materials to real engineering situations should be emphasised. The use of a case-study based approach is also encouraged. Engineering Failure Analysis provides essential reference material and critical feedback into the design process thereby contributing to the prevention of engineering failures in the future. All submissions will be subject to peer review from leading experts in the field.