Ply-overlap technique for joining dissimilar/hybrid composite materials

Hybridisation of multiple materials is emerging as a key strategy to achieving high performance lightweight structures while keeping the cost low. Fundamental to creating strong and cost-effective hybrid composites is the ability to efficiently join dissimilar materials. Herein we present a novel co-curing ply-overlap joint technique for integrating dissimilar composite materials. Experimental studies are conducted to identify the dominant failure mechanisms and the effect of design parameters, such as the spatial distances between ply terminations and overlap length, on the strength of hybrid composite ply-overlap joints. To enable optimisation of ply-overlap joints, analytical and computational models are developed and validated against the experimental data. The results demonstrate that ply-overlap joints are capable of approaching the un-notched strength of the glass composite material. The validated predictive tools enable design optimisation of hybrid composite structures.