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The load capacity of long adhesive lap joints is often governed by stress concentrations at the lap ends. This paper investigates a method to minimize these stress concentrations by using a bond line with low shear stiffness and sufficient strength, here denoted as a resilient bond line. The resilient bond line is intended to increase the load carrying capacity of long lap joints by achieving a more uniform shear stress distribution while maintaining an elastic joint behaviour without damage or plastic deformation. The study comprises analytical, numerical and full-sized experimental work on double lap joints with lengths 200–700 mm comparing conventional stiff bond lines to resilient bond lines. Different resilient bonds lines were obtained by using rubber-like adhesives and by having a rubber mat within the bond line. An analytical definition of a ‘long’ lap joint is suggested and a study of adhesive-rubber bonding is also presented. The numerical analysis clearly indicates that an increase in load carrying capacity is made possible using resilient bond lines. A good agreement is also found between the numerical results and the analytical Volkersen theory, indicating that reasonable strength predictions can be obtained by hand calculations if the joint is designed in order to minimize the influence of peel stress. The experimental results of the resilient bond line verify the numerical findings, although production difficulties decrease the statistical significance of the result. On the contrary, the experimental results of the conventional bond lines significantly exceeded the numerical predictions, showing similar load carrying capacities to the resilient bond line. This is probably due to the specific boundary conditions used in the test setup. Despite some contradictory experimental results, the conclusion of this study is that the efficiency of long lap joints can be increased by the use of a bond line with low shear stiffness and sufficient strength

Use of a resilient bond line to increase strength of long adhesive lap joints