Mechanical performance and failure behaviour of miniature aluminium joints with novel interlocking reinforcement

Abstract A novel hybrid joining method is proposed which consists of adhesive joints reinforced with mechanically interlocking surface features. The present work focuses on single interlocking features formed in the centre of the bond region of miniature single lap joints. The joints were loaded under single lap shear conditions to examine the interlocking feature's effect on joint failure load and work to failure. Results indicate that significant improvements of up to 27% and 542% are obtained in joint failure load and work to failure, respectively. These improvements are caused by the feature altering the stress states present in the adhesive, impeding crack propagation through the bond line and creating a more progressive failure path as compared to a standard flat bonded joint.