Joining Carbon Fiber Sheets: Evaluating Adhesive Bonding, Bolted Joints, and Riveting for Structural Integrity

nlike metals, carbon fiber composites cannot be welded—and improper joining methods can trigger delamination, fiber crushing, or galvanic corrosion. Selecting the right connection strategy is therefore critical to maintaining structural continuity and load transfer efficiency.
Adhesive bonding is often optimal: it distributes stress evenly across the joint, avoids drilling-induced damage, and preserves the composite’s monolithic nature. High-performance epoxies or acrylics with peel-resistant formulations are recommended. Surface abrasion and plasma treatment enhance bond strength.
Bolted joints offer disassembly flexibility but require oversized holes, chamfered edges, and non-metallic washers to prevent stress concentration and galvanic coupling (especially with aluminum fasteners). Torque must be carefully controlled.
Riveting is generally discouraged unless using specialized composite-compatible rivets (e.g., titanium or polymer-based), as traditional rivets can crack the brittle matrix during installation.
For dynamic or fatigue-prone assemblies, adhesive bonding combined with light mechanical backup (e.g., pins) often provides the best balance of reliability and serviceability.
Remember: in composites, how you join is as important as what you join.
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