Simulating damage and delamination in fibre metal laminate joints using a three-dimensional damage model with cohesive elements and damage regularisation

This paper investigates the capability of a three-dimensional finite element model with damaging material behaviour, cohesive elements and damage regularisation to simulate complex damage patterns in fibre metal laminate (FML) joints. The model incorporates a three-dimensional continuum damage mechanics approach for the composite plies, a plasticity model for the aluminium layers, and a delamination model between layers. A nonlocal averaging scheme is implemented to mitigate the mesh sensitivity that occurs with strain-softening material models. Bearing stress–strain responses and variations in stiffness are calculated, and damage progression is described in detail for all plies and interfaces. Microscopy and stress–strain data from a parallel series of experimental tests are presented, and damage and failure phenomena observed in the tests are compared with the model. Generally, good agreement between model and tests was achieved but certain limitations of the numerical model were observed and are discussed. The combined numerical and experimental information provide a detailed understanding of the failure sequence of FML joints.