Damage evolution modeling of CFRP/Al single-lap screw type blind riveted joints during realistic installation process

As studies on the damage behaviors of composites during screw type blind riveting are notably absent, this paper seeks to fill this gap by combining experimental tests and numerical simulation methods. A three-dimensional finite element model was proposed, and the simulation results were obtained and validated by experimental data. The light microscope and scanning electron microscope were used to observe the stress state, axial deformation, damage modes, and damage distribution in two load-bearing regions at the initial contact and after installation. The results demonstrated that the preload showed a four-step “zero -steep rise -decline -steep rise” development during installation. The stress and deformation were concentrated in two circular zones, with the maximum axial stress component and deformation of 321 MPa and 0.046 mm, respectively. In two pressed zones, there were three failure modes, with out-plane matrix crushing being the most severe. In-plane matrix cracking damage is seen at a 45° direction in the first layer, with a damage index of 0.745. In addition, the effect of two geometric parameters of the sleeve on the blind head shape, load-bearing regions, and CFRP damage was investigated. The results would build confidence in reducing CFRP damage and enhancing joint integrity.