Dynamic Influence of Hole Geometry on Hybrid GFRP/Al Joint Performance

This study investigates the influence of joining parameters on the dynamic tensile performance of hybrid bonded-bolted GFRP/Al joints, which are crucial in aerospace and automotive applications due to their high strength and lightweight properties. The motivation lies in addressing challenges related to geometric imperfections and varying assembly conditions that significantly impact joint reliability under dynamic loads. Experiments and numerical simulations were conducted to evaluate the effects of perpendicularity errors, fit clearance, and preload on the mechanical performance and failure modes of these joints. Dynamic tensile tests were performed using controlled loading conditions, and finite element modeling was employed to validate experimental findings and provide additional insights into stress distributions and failure mechanisms. The results demonstrated that perpendicularity errors significantly degrade joint performance. Specifically, joints with a 3° perpendicularity error parallel to the load direction exhibited a 64.40% reduction in energy absorption, whereas errors perpendicular to the load direction resulted in a 31.09% reduction. Excessive fit clearance changed the failure mode from tensile to shear, particularly at lower loading speeds. Increasing the preload effectively delayed adhesive layer delamination, reduced deformation, and enhanced overall joint strength. This research provides novel insights into the effects of geometric errors and assembly conditions on hybrid joint performance.