Numerical design and multi-objective optimisation of novel adhesively bonded joints employing interlocking surface morphology

A novel concept for joining materials is presented which employs adhesive joints with interlocking bond-surface morphology formed on the surfaces of male and female adherends that mechanically interlock in shear when brought together. In the present work, miniature, single-lap joint specimens with a single truncated square pyramid interlocking profile, centred in the bond area, are investigated. The performance of the concept is assessed through finite element analysis (FEA) by incorporating yield criteria representing plasticity in the adherends and a cohesive zone model to represent damage in the adhesive layer. This allows for effective simulation of the joint response until ultimate failure and thus, full assessment of the concept's performance. Various interlocking geometries are explored and refined through an adaptive surrogate modelling design optimisation procedure coupled with FEA. The results indicated that significant improvements in work to failure, of up to 86.5%, can be achieved through the more progressive failure behaviour observed compared to that of a traditional adhesively bonded joint. Improvements in the joint's ultimate failure load can also be achieved with a relatively ductile adhesive system.