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Scaling Effects in Adhesively Bonded Composite Joints: The Influence of Laminate Thickness on the Structural Efficiency of Single Strap Configurations
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DOI：10.1016/j.ijadhadh.2026.104358.png)
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Abstract
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Adhesively bonded Single Strap Joints (SSJs) are commonly used in aerospace and marine structures to maintain surface flushness, yet their inherent load eccentricity makes them susceptible to elevated peel stresses compared to Single Lap Joints (SLJ). This study experimentally and numerically investigates the influence of adherend and strap thickness on the structural performance of quasi-isotropic woven carbon-epoxy joints, with a specific focus on quantifying geometric scaling effects. Tensile tests were conducted on 8-ply and 12-ply laminates in both configurations. Two non-dimensional parameters, Joint Efficiency and Geometric Efficiency, were introduced to benchmark the performance. The results revealed a distinct non-linear scaling behavior: while the thinner 8-ply SSJ demonstrated high viability, retaining 89.3% of the SLJ baseline strength, the 12-ply SSJ exhibited a sharp decline, retaining only 55.6%. Separately, the effect of strap stiffness was isolated, revealing that increasing the strap thickness from 8 to 12 plies resulted in negligible improvement in load capacity. Finite Element Analysis confirmed that adherend damage initiates before the adhesive is fully utilized in thicker joints, driving a transition from Fiber Tear to premature delamination. The findings highlight a practical design limitation, concluding that standard SSJs possess poor geometric efficiency for thick laminates and necessitate alternative design strategies to mitigate peel-driven failure mechanisms.
Keywords:
Adhesively bonded joints
Single Strap Joints
Geometric scaling
Composite laminates
Peel stress
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