Abstract:
Riveted-bonded hybrid joining method is widely used in the connection between carbon fiber reinforced polymer (CFRP) and metals due to its high load-bearing capacity and good service performance. However, fatigue-induced damage in multi-materials poses a critical threat to structural safety and service life. For the CFRP/aluminum alloy riveted-bonded hybrid joints, a multi-material fatigue life simulation-based prediction method was proposed based on the damage contribution. The failure competition evolution law of CFRP/ aluminum plate/ rivet under different load levels was explored through experiments. Meanwhile, the influences of parameters such as adhesive layer thickness, overlap length and number of rivets on its fatigue life were also investigated. The results show that the fatigue life of the adhesive-riveted hybrid joint is significantly affected by the coupling of multiple parameters. When the overlap length is small and the number of rivets is low, the fatigue life decreases nonlinearly with the increase of the adhesive layer thickness. When the thickness of the adhesive layer is fixed, the influence of the lap length on the fatigue life is non-monotonic, and the optimal value depends on the adhesive layer thickness and the load level. It is further found that the influence of the number of rivets on the fatigue life shows a significant dependence on the load level. Meanwhile, the numerical simulations demonstrate good agreement with experimental data, with relative errors of fatigue life prediction constrained within ±10%. The validated models reliably capture the fatigue failure modes of hybrid joints, providing critical references for fatigue-resistant optimization of composite-metal hybrid connections.