A maximum stress at a distance criterion for the prediction of crack propagation in adhesively-bonded joints

► The prediction of the mode I failure of adhesive joints is considered. ► Values of the maximum stress/critical distance for fracture have been determined. ► These values have been interpreted in terms of the identified physical mechanisms. ► Accurate numerical simulations have been undertaken employing these values. ► A non-dimensional study enables these results to be transferred to other adhesives. The present work relates to the numerical prediction of the mode I failure of metal-to-metal adhesive joints under quasi-static, steady-state conditions by means of a criterion based on attaining a critical value of the maximum principal stress at a critical distance ahead of the crack tip. The model accurately predicts the failure of three adhesives (i) over a wide range of the thickness of the adhesive layer from 0.1 to 1mm, and (ii) for two very different test geometries: namely the linear elastic fracture-mechanics tapered double-cantilever beam test and the elastic–plastic fracture-mechanics wedge-peel test.