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<p>Assembly gaps caused by manufacturing tolerances are common in carbon fiber-reinforced polymer (CFRP) structures and are typically addressed by forced assembly or gap compensation. This study investigates CFRP-Al single-bolt single-lap joints under quasi-static tensile loading for both assembly strategies. Digital image correlation (DIC) and scanning electron microscopy (SEM) were used to capture deformation and damage evolution, and a user-defined material subroutine (UMAT) was developed to model progressive damage. For a fixed gap length of 15&#xa0;mm, the influence of gap height on joint stiffness, load-carrying capacity, and failure mechanisms was systematically examined. The results show that forced assembly induces structural bending and bolt inclination, leading to bending-driven tensile-shear damage and a progressive reduction in ultimate load with increasing gap height, although small gaps may locally increase stiffness. In contrast, gap compensation redistributes bolt preload through a compliant shim, suppressing global bending and shifting the dominant failure mode to bearing-controlled surface crushing beneath the bolt head. However, tensile stiffness is generally reduced and becomes sensitive to shim thickness. A transition between bending- and bearing-dominated failure modes is governed by gap height. Forced assembly is suitable for small gaps (≤ 0.8&#xa0;mm(the ratio of gap height to plate thickness ≤ 1/3)), whereas gap compensation is required for larger gaps to ensure structural integrity.</p>

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Effects of Forced Assembly and Gap Compensation on the Tensile Response and Failure Behavior of CFRP-Al Single-Bolt Single-Lap Joints

  • 期刊论文

  • 发表日期：

    2026年6月29日

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  • Tianchun Zou,
  • Yuhang Yin,
  • Guoqiang He

摘要

Assembly gaps caused by manufacturing tolerances are common in carbon fiber-reinforced polymer (CFRP) structures and are typically addressed by forced assembly or gap compensation. This study investigates CFRP-Al single-bolt single-lap joints under quasi-static tensile loading for both assembly strategies. Digital image correlation (DIC) and scanning electron microscopy (SEM) were used to capture deformation and damage evolution, and a user-defined material subroutine (UMAT) was developed to model progressive damage. For a fixed gap length of 15 mm, the influence of gap height on joint stiffness, load-carrying capacity, and failure mechanisms was systematically examined. The results show that forced assembly induces structural bending and bolt inclination, leading to bending-driven tensile-shear damage and a progressive reduction in ultimate load with increasing gap height, although small gaps may locally increase stiffness. In contrast, gap compensation redistributes bolt preload through a compliant shim, suppressing global bending and shifting the dominant failure mode to bearing-controlled surface crushing beneath the bolt head. However, tensile stiffness is generally reduced and becomes sensitive to shim thickness. A transition between bending- and bearing-dominated failure modes is governed by gap height. Forced assembly is suitable for small gaps (≤ 0.8 mm(the ratio of gap height to plate thickness ≤ 1/3)), whereas gap compensation is required for larger gaps to ensure structural integrity.