Influence of accelerated corrosion on bi-material steel-CFRP double-lap joints bonded with thick adhesive

Abstract

Bi-material steel-composite joints attract interest for marine applications. The marine environment imposes corrosion which is a prolonged process. This work presents a two-electrode electrochemical setup for accelerating free corrosion of the steel surfaces of bi-material joints. It is used to study the impact of accelerated corrosion on the mechanical performance of bi-material double lap specimens subjected to quasi-static tensile testing. Several test series have been conducted to evaluate the influence of overlap length and bond line thickness on shear strength and failure mode. Sixty specimens with a thick layer of methyl methacrylate adhesive have been fabricated and cured at room temperature for at least 24 h. Subsequently, 30 specimens were aged by subjecting them to electrochemical corrosion for 24 h. All specimens were tested for failure in quasi-static tensile loading while monitoring the strain fields in the joint area using digital image correlation. The measurements reveal a homogeneous shear strain field at the onset of loading, with a rapidly increasing shear strain concentration near the edges of the bond line preceding final failure. Both a decrease in the adhesive thickness and an increase in the overlap length increase the shear strength. Higher shear strength was observed for the electrochemically aged specimens than that of non-aged specimens. This is attributed to the faster residual curing of the adhesive during ageing because an increasing percentage of copper ions (released from the anode) accelerates the curing of the MMA adhesive. The electrochemically aged specimens showed mixed failure modes, i.e. cohesive failure and adhesive failure at the interface between steel and adhesive, and skin failure within the composite laminates.