Residual Strength of Adhesively Bonded Joints Under High-Velocity Impact: Experimental and Numerical Investigation of Impact-Induced Degradation

Adhesively bonded joints are extensively utilized in structural assemblies involving metals, composites, and hybrid materials due to their favorable mechanical and manufacturing characteristics. However, their performance under high-velocity impacts—common in aerospace, automotive, and defense applications—remains insufficiently understood. This work investigates the high-velocity performance and subsequent tensile response of adhesively bonded single-lap joints (SLJs) by integrating experimental testing with numerical simulations. High-velocity impacts were applied to SLJs fabricated from 4 mm aluminum adherends with overlap lengths of 15 mm and 25 mm, using a 1.25 g projectile at 288 m/s, followed by quasi-static tensile assessment. Experimental findings revealed substantial degradation in tensile strength for the 15 mm overlap configuration (reduced the load-bearing capacity by about 33% (from ~12 kN to ~8 kN)), while the 25 mm overlap retained its structural integrity. Finite element simulations conducted in ABAQUS 2021 employed the Johnson–Cook constitutive model for the adherends and a cohesive zone model for the adhesive layer, successfully replicating damage evolution and stress distributions. The results highlight the critical role of geometric parameters—particularly overlap length and adherend thickness—in determining the damage tolerance and residual load-bearing capacity of SLJs subjected to high-velocity impacts. These insights contribute to the development of more robust bonded joint designs for impact-prone environments.