Progressive Failure Analysis of Composite/Aluminum Riveted Joints Subjected to Pull-Through Loading

Abstract Out-of-plane mechanical properties of the riveted joints restrict the performance of the wing box assembly of airplane. It is necessary to investigate the pull-through performance of the composite/metal riveted joints in order to guide the riveting design and ensure the safety of the wing box assembly. The progressive failure mechanism of composite/aluminum riveted joint subjected to pull-through loading was investigated by experiments and finite element method. A progressive damage model based on the Hashin-type criteria and zero-thickness cohesive zone method was developed by VUMAT subroutine, which was validated by both open-hole tensile test and three-point bending test. Predicted load-displacement response, failure modes and damage propagation were analysed and compared with the results of the pull-through tests. There are 4 obvious characteristic stages on the load-displacement curve of the pull-through test and that of the finite element model: first load take-up stage, damage stage, second load take-up stage and failure stage. Relative error of stiffness, first load peak and second load peak between finite element method and experiments were 8.1%, − 3.3% and 10.6%, respectively. It was found that the specimen was mainly broken by rivet-penetration fracture and delamination of plies of the composite laminate. And the material within the scope of the rivet head is more dangerous with more serious tensile damages than other regions, especially for 90° plies. This study proposes a numerical method for damage prediction and reveals the progressive failure mechanism of the hybrid material riveted joints subjected to the pull-through loading.