Numerical prediction on the fatigue debonding behaviour in a complex bi-material interface: A case study on wrapped composite joints

Debonding is one of the most critical failure modes for bonded joints under fatigue loads. Numerical prediction on the fatigue debonding behaviour of bonded interfaces with complex geometry still remains a problem. This paper proposes a numerical methodology based on fracture mechanics to predict crack growth in a complex bi-material interface and illustrates the prediction procedure by a case study on wrapped composite joints. Interface coupon tests provide the fatigue crack growth properties at the composite-to-steel interface used as inputs for finite element (FE) modelling. The FE model is calibrated against fatigue tests of small scale wrapped composite joints with different steel surface roughness subject to different load levels. A sensitivity analysis is conducted to investigate the influence of key modelling parameters. The calibrated model is validated against fatigue tests on upscaled joints. Good agreements are shown between the test and modelling results in terms of crack growth and stiffness degradation, demonstrating the potential of the proposed numerical methodology for predicting fatigue debonding behaviour of complex bi-material interfaces. • Fatigue debonding at complex bi-material interfaces is predicted numerically. • Interaction of debonding at different crack paths is predicted. • Modelling parameters are calibrated by small scale wrapped composite joint tests. • The numerical model is validated through upscale joint tests.