Quantitative Design and Residual Strength Assessment of Adhesive-Rivet Hybrid Repairs for Perforated Aluminum Alloy Plates
Abstract
Perforation damage can significantly reduce the load-carrying capacity of aluminum alloy plates. Adhesive-rivet hybrid repair combines the continuous load-transfer capability of adhesive bonding with the reliable mechanical connection provided by riveting; however, quantitative methods for matching damage size, rivet parameters, and adhesive load-carrying capacity remain insufficient. In this study, perforated 2A12-T4 aluminum alloy plates were investigated. Based on the equal-strength criterion and load-transfer equilibrium, a strength-matching relationship between the adhesive layer and blind rivets was established, and a residual-strength assessment method for the repaired structure was proposed. Two typical two-part epoxy adhesives with different shear strengths, Araldite-2015 and Lord 320/322, which have application backgrounds in aerospace structural joining and repair, were selected. Combined with blind rivets of different load-carrying capacities, they formed strong-adhesive/weak-rivet and weak-adhesive/strong-rivet configurations to investigate the mechanical response under different adhesive-rivet strength-matching conditions. Quasi-static tensile tests, digital image correlation (DIC) measurements, and finite element analyses incorporating a cohesive zone model and a ductile damage criterion were performed to investigate load distribution and failure behavior. The results show that the maximum deviation between the finite element predictions and the experimental…
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