Tubular composite joints offer a non-welded alternative for offshore structures by bonding a composite wrap to steel Circular Hollow Section (CHS) members, eliminating weld-induced stress concentrations and significantly improving fatigue life. This enables steel weight and cost reductions and faster fabrication for jacket structures supporting large off-shore wind turbines. In service, these joints experience complex cyclic loads combining axial forces and bending moments, which can lead to interfacial debonding and delamination, necessitating damage-tolerant design. This paper presents one of the first experimental campaigns applying combined axial and bending loads on composite X-joints using a Hexapod system, enabling realistic offshore load simulation. Fatigue tests on 1/4-scale X90 specimens cover pure axial tension, out-of-plane bending, and combined cases. Two primary failure modes were observed: interfacial debonding under compressive strain and delamination under tensile in-plane strain. A numerical methodology based on the Virtual Crack Closure Technique (VCCT) and a stepwise crack-growth model incorporating non-linear crack retardation effects, rarely considered in composite joint fatigue modelling, was developed. Calibration of the Paris-law constant C revealed variations up to two orders of magnitude due to interface quality and manufacturing variability. Despite this, results demonstrate fatigue life extensions of up to 2000 times compared to welded joints. This work introduces a design philosophy leveraging crack retardation and interface friction effects to predict fatigue life, moving beyond conservative stress-based criteria towards damage-tolerant offshore design.

The wrapped composite joints have been introduced as a new technology to connect steel circular hollow sections of support structures for offshore wind turbines. The design and implementation of this innovation require predicting the effects of environmental conditions on the mechanical performance of the structure. In particular, temperature changes can generate interfacial stresses along the bonded interface between the two dissimilar materials, affecting the performance of the structure. This work aims to investigate the effect of short-term changes of temperature on the mechanical behavior of a wrapped composite joint. Specimens were produced with two steel tubes wrapped by a glass fiber composite laminate. Mechanical tests were performed under fatigue and static loading conditions. Experiments are carried out at room temperature (21 ℃) as well as at non-ambient temperature using a climate chamber at –10 ℃ 50 ℃ and 70 ℃. Results revealed that lower temperatures improve the performance of wrapped composite joints under both fatigue and static loading conditions. This points to a significant contribution of the thermally-induced effects on the performance of the structure due to the different coefficients of thermal expansion of the steel and composite materials. Experimental results obtained from this work can be applied to create numerical models capable of predicting the mechanical behavior of wrapped composite joints in different temperatures.

This work focuses on investigating the effect of short-term changes of temperature on the mode I and mode II glass fibers woven composite interleaved with layers of chopped strand mat (CSM). Existing experimental and numerical methods are critically applied to characterize and model the delamination of the woven-CSM composite laminate. Double cantilever beam (DCB) and end notched flexure (ENF) tests are performed in non-post cured and post cured specimens at room temperature (21 °C), and the operational conditions are investigated on post cured specimens tested in low (−10 °C) and high (70 °C) temperatures. The fracture behavior is characterized using the compliance-based beam method (CBBM) while crack length estimations based on the specimen compliance are compared to direct measurements from digital image correlation (DIC). Then, a failure analysis was performed using an optical profilometer and scanning electron microscopy (SEM). Temperature changes affected the preferential crack path for the woven composite delamination in mode I loading conditions. However, the crack path in mode II fracture remained independent of the testing temperature. Fractography results revealed temperature-dependent failure mechanisms, with an increase of fiber/matrix interface debonding and matrix deformation in higher temperatures. The higher matrix ductility translated into an improvement of the delamination fracture toughness in both mode I and mode II loading conditions. Finally, non-linear cohesive models directly derived from experimental results were capable to accurately reproduce the mode I and mode II delamination fracture behavior of the woven-CSM composite in different temperatures.

Hybrid structures built with composite and steel emerge across industries (offshore, shipbuilding, bridges, etc.) due to benefits of weight optimization, fatigue and environmental resistance. Particularly, the wrapped composite joints emerge as a new method to connect steel circular hollow sections for application in supporting structures of offshore wind turbines. The implementation of this technology requires predicting the long-term performance of the bi-material interface under operational conditions of loading and environment. This work addresses the effects of temperature and saltwater aging on the fatigue crack growth behavior of the composite-steel bonded joint under mode II loading conditions. Fatigue tests were performed using a 4-point end-notched flexure (4ENF) set up with digital image correlation (DIC). A numerically based method was applied to calculate the strain energy release rate (SERR) accounting for friction effects, geometrical and material non-linearities. The consistency of the manufacturing process was evaluated by tests performed in room conditions (21 °C). The mode II fatigue behavior of the composite-steel bonded joints remained between an upper and a lower bound of the Paris curves, characterized by composite delamination and adhesive failure, respectively. Then, the effect of temperature was assessed by experiments in −10 °C and 70 °C. Short-term temperature changes showed a significant effect on the fatigue resistance of the bonded joint, followed by changes in the failure mode. Finally, a decrease in performance was observed as a consequence of the long-term aging of specimens in saltwater for up to 549 days.

Debonding is characterized as the governing failure mode in the innovative wrapped composite joints made with glass fiber composite material wrapped around steel hollow sections without welding. The prerequisite for predicting debonding failure of wrapped composite joints is to obtain fracture behavior of the composite-steel bonded interface. The mode I fracture behavior of the bonded interface was experimentally investigated using glass fiber composite-steel double cantilever beam (DCB) specimens. The crack length a and the crack tip opening displacement (CTOD) during the test were accurately measured by analyzing the digital image correlation (DIC) data while the strain energy release rate (SERR) was calculated through the extended global method (EGM). The cohesive zone modeling (CZM) was utilized in the finite element model with the proposal of a four-linear traction-separation law to simulate the mode I fracture process. An approach is introduced to determine the critical stages of the proposed four-linear cohesive law by combining accurate measurements of crack length a and CTOD, along with SERR values. The validity of the four-linear cohesive law and the introduced approach to determine the critical stages were confirmed by good agreement in both global and local behavior between the testing and the FEA results.

In this paper, mode II fatigue crack growth properties of the composite-to-steel interface are characterised through different test configurations, namely ENF and 4ENF tests. Different loading types including force control and displacement control methods are compared. An innovative shear strain based method is proposed for monitoring the mode II crack growth at the bi-material interface through Digital Image Correlation (DIC). A 3D finite element model with Virtual Crack Closure Technique (VCCT) is built and used for obtaining the strain energy release rate (SERR) to investigate the effect of geometrical nonlinearity, friction at the interface and steel yielding, as well as to verify the mode mixity. The results show that the standard 3-point bending ENF specimen can be unstable under force control and sweeps narrow SERR range by a single test under displacement control. The 4-point bending 4ENF test shows stable crack propagation and clear SERR developing trend. More pronounced geometrical nonlinearity and friction effect exist for 4ENF test which can be considered when interpreting the Paris curves by a nonlinear finite element model.

Hybrid bi-material concepts in engineering structures where fibre-polymer composites are used together with steel structural members have potential to reduce material usage, extend fatigue life and improve structural reliability. The bond performance of the bi-material composite-to-steel interface is of crucial importance and highly relies on the surface preparation quality of the steel element. This paper investigates the influence of steel surface roughness on the mode II fracture toughness and fatigue crack growth behaviour of the bonded composite-to-steel joints. Glass fibre composite and mild structural steel material is considered directly bonded in a wet lay-up process. 4-point end notch flexure (4ENF) tests are conducted on specimens with the steel plates prepared with low, medium and high roughness, respectively. In addition, morphology of the fracture surfaces are characterised by a 3D profilemeter and the friction coefficient is measured by a tribometer for each roughness level. Results show that in quasi-static fracture, fibre bridging is dependent on the surface roughness. A roughness level with S_q ≥ 22 µm of the steel surface can promote significant fibre bridging thus improved fracture toughness due to enlarged effective bonding area. Under cyclic loading, no fiber bridging is observed across all roughness levels tested. However, the Paris curve parameter C is significantly affected by the roughness level, which decreases by approximately 100 times as the steel surface roughness increases from the low level of S_q = 5 µm to high level of S_q = 22 µm. The m parameter of the Paris curve remains fairly constant across all the roughness levels tested.

This chapter discusses the mixed-mode loading of adhesive joints. The importance of mixed-mode loading is first introduced and then test methods commonly used to measure the mixed-mode fracture resistance of adhesive joints are presented and briefly discussed. The approaches to determine the fracture resistance are briefly reviewed and then the partitioning of mixed-mode fracture energies is discussed. The limitations of the local singular field and global approaches to mixed-mode partitioning are discussed and the use and application of a semianalytical cohesive zone analysis partitioning scheme is evaluated. The limitations of the global partitioning approach are further discussed in the context of developing a scheme to design and analyze adhesive joints with dissimilar adherends (a bi-material interface). A longitudinal strain criterion is proposed in addition to the matching of flexural rigidities and the approach is validated numerically. Finally, the practical issues of crack stability, failure path selection, and the use of mixed-mode failure envelopes is considered.

The goal of this paper is to evaluate the strain-based partitioning method (SBM), an analytical method based on beam analysis, for the mixed-mode fracture characterization of asymmetric cracks. The fracture energy is calculated at the crack tip of mixed-mode bending (MMB) test with asymmetric geometry and asymmetric material parameters. The fracture energy obtained using SBM is benchmarked against the widely applied Williams’ partitioning method (WM) and numerical results from finite element models using the virtual crack closure technique (VCCT). Results show that WM produces inaccurate fracture modes in asymmetric conditions. However, if using SBM, the fracture mode ratio of bi-material cracks was obtained with accuracy. SBM describes a coupling function between mode I and mode II fracture that allows the mode partitioning as long the specimen complies with a simple design criterion based on the longitudinal strain equivalence between arms. Experimental results of composite-to-metal bonded joints validate the results of the parametric study. SBM proves to be an easy and reliable solution for the mixed-mode fracture characterization of bi-material cracks.

In this work, the influence of a layer of glass fiber mat (GFM) inserted in a bi-material bonded joint interface is investigated as a toughening mechanism to improve the fracture performance of bonded structures. Composite-to-metal bonded specimens were manufactured by hand lay-up using two different consolidation processes: at room pressure or using vacuum bagging. The fracture behavior was evaluated under quasi-static loadings using the mixed-mode bending (MMB) test. Test results revealed an increase of the fracture toughness with the insertion of an adjacent layer of GFM. The toughening mechanism is associated with a more irregular fracture surface profile. It was verified a relationship between the fracture surface roughness and the fracture toughness. The toughening effect showed to be more evident in higher mode II fracture conditions. The insertion of a layer of GFM and the use of vacuum pressure in the consolidation of the composite increase the fracture performance of composite repairs in metal structures.

The dissemination of composite materials introduces applications of hybrid structures with composite and metal parts. The development of reliable methodologies to evaluate the performance of these structures is required. In this work, the mixed-mode fracture behaviour of a bi-material adhesively bonded joint is investigated. A new strain-based criterion for the design of the mixed-mode bending (MMB) bi-material specimen is suggested. A new analytical partitioning method based on the ‘global method’ is proposed and tested on a composite-to-metal bonded joint and compared with a finite element model using the virtual crack closure technique (VCCT). The results show that the proposed strain-based design methodology can be successfully used in MMB test for bi-material joints. The fracture mode partitioning is accurately predicted by the analytical method. However, the absolute values of the strain energy release rate (SERR) predicted by the analytical method are only accurate if the shear deformation in the test is not significant.

In this work, an experimental study has been carried out to evaluate the effect of salt water condition on the long-term adhesion of composite-to-metal bonded joints using peel tests. A new test configuration is tested via fully and partially immersed specimens with 500 mm length. Fracture surfaces of non-aged samples exhibited a cohesive failure within the adhesive layer, which indicates a good adhesion of the joint. Results revealed a significant difference in the interface adhesion between aged and non-aged condition after 150 days of immersion. Partially immersed specimens allow to evaluate the adhesion performance of the joint under dry and wet condition in single specimen using a simple peel test.