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<p>To meet the load-bearing and sealing requirements of integral aircraft fuel tanks, hybrid bonded/bolted joints are widely employed in critical connections. However, defects induced by thermo-chemo-mechanical coupling during the curing process of the adhesive layer significantly compromise structural integrity and sealing performance. In this study, the curing reaction kinetics of the XM22-A sealant were accurately characterized using differential scanning calorimetry (DSC), and the relationships between key thermophysical parameters with temperature and curing degree were established. A three-dimensional finite element model integrating curing kinetics, heat transfer, and a viscoelastic constitutive model was developed to simulate the evolution of temperature, cure degree, and residual stress during curing. The curing subroutine was validated, showing a maximum deformation displacement error of approximately 7.5% in the cantilever beam simulation compared to experimental data. The results revealed significant concentrations of residual stress and deformation displacement at the laminate joint and adhesive layer edges. A novel defect evaluation method was proposed, combining von Mises stress and deformation displacement into a comprehensive index weighted by the entropy weight method. Validation via scanning electron microscopy and industrial computed tomography confirmed that the model’s predictions of defect-prone regions align well with experimental observations. This study provides a reliable theoretical framework for accurate prediction and control of defects in adhesive layers, which is crucial for ensuring the sealing reliability of aerospace polymer composite structures.</p>

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Curing Reaction Kinetics-Based Modeling and Defect Prediction in Adhesive Layers of Composite Hybrid Bonded/Bolted Joints

  • 期刊论文

  • 发表日期：

    2026年5月2日

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  • Di Zhao,
  • Wenhua Deng,
  • Chaohua Yang,
  • Cui Wang,
  • Bin Luo

摘要

To meet the load-bearing and sealing requirements of integral aircraft fuel tanks, hybrid bonded/bolted joints are widely employed in critical connections. However, defects induced by thermo-chemo-mechanical coupling during the curing process of the adhesive layer significantly compromise structural integrity and sealing performance. In this study, the curing reaction kinetics of the XM22-A sealant were accurately characterized using differential scanning calorimetry (DSC), and the relationships between key thermophysical parameters with temperature and curing degree were established. A three-dimensional finite element model integrating curing kinetics, heat transfer, and a viscoelastic constitutive model was developed to simulate the evolution of temperature, cure degree, and residual stress during curing. The curing subroutine was validated, showing a maximum deformation displacement error of approximately 7.5% in the cantilever beam simulation compared to experimental data. The results revealed significant concentrations of residual stress and deformation displacement at the laminate joint and adhesive layer edges. A novel defect evaluation method was proposed, combining von Mises stress and deformation displacement into a comprehensive index weighted by the entropy weight method. Validation via scanning electron microscopy and industrial computed tomography confirmed that the model’s predictions of defect-prone regions align well with experimental observations. This study provides a reliable theoretical framework for accurate prediction and control of defects in adhesive layers, which is crucial for ensuring the sealing reliability of aerospace polymer composite structures.