The Effect of Adhesive Layer Thickness on Joint Static Strength

One of the most relevant geometrical factors defining an adhesive joint is the thickness of the adhesive layer. The influence of the adhesive layer thickness on the joint strength has not been precisely understood so far. This article presents simplified analytical formulas for adhesive joint strength and adhesive joint coefficient for different joint loading, assuming, inter alia: linear-elastic strain of adhesive layer, elastic strain of adherends and only one kind of stress in adhesive. On the basis of the presented adhesive joint coefficient, the butt joint was selected for the tests of the influence of adhesive thickness on the adhesive failure stress. The tests showed clearly that with an increase in the thickness of the tested adhesive layers (up to about 0.17 mm), the value of their failure stress decreased quasi linearly. Furthermore, some adhesive joints (inter alia subjected to shearing) may display the optimum value of the thickness of the adhesive layer in terms of the strength of the joint. Thus, the aim of this work was to explain the phenomenon of optimal adhesive layer thickness in some types of adhesive joints. The verifying test was conducted with use of single simple lap joints. Finally, with the use of the FE method, the authors were able to obtain stresses in the adhesive layers of lap joints for loads that destroyed that joints in the experiment, and the FEM-calculated failure stresses for lap joints were compared with the adhesive failure stresses determined experimentally using the butt specimens. Numerical calculations were conducted with the use of the continuum mechanics approach (stress-based), and the non-linear behavior of the adhesive and plastic strain of the adherends was taken into account.