The Effect of Fillet Geometry on Stress in Weld-Bonded Joints

Abstract

The influence of fillets with different geometry shape on the stress distribution in aluminum alloy weld-bonded single lap joint was investigated using elasto-plastic finite element method (FEM). The results show that it is advantageous of reducing stress concentration in adhesive layer near the ends of the lap zone in single lap weld-bonded aluminum joints and part of the stress transferring from adhesive layer to the nugget when the joints with a couple of right triangle fillets over other shapes. The load-bearing capacity of the whole weld-bonded joints may be improved. The full-triangular fillet is recommended that it be more advantageous of decreasing the stress peak value and making the stress distribution in overlap zone more uniform.