Corrosion-Induced Degradation Mechanisms and Bond–Slip Relationship of CFRP–Steel-Bonded Interfaces
Abstract
1. Introduction
2. Experimental Program
2.1. Materials and Specimens
2.2. Specimen Grouping and Experimental Variables
2.3. Accelerated Procedure to Generate Corrosion Damage
2.4. Instrumentation and Loading Procedure
3. Results and Discussion
3.1. Corrosion Morphology and Mass Loss
3.2. Effect of Corrosion Damage
3.3. Effect of GFS in the Adhesive Layer
3.4. Effect of CFRP Bond Length
4. Bond–Slip Behaviour
4.1. Longitudinal Axial Strain Along the CFRP Plate
4.2. Establishment of the Bond–Slip Model
5. Conclusions
- The electrochemical corrosion method adopted in this study enables the controlled and efficient generation of different corrosion damage levels calibrated to ISO 9223 [21], providing a practical basis for investigating corrosion-induced degradation of CFRP–steel-bonded joints. The measured steel plate mass loss is almost consistent with the predicted mass loss. It is observed that the obvious corrosion only occurs on the steel plates, and there are corrosion pits on the steel surfaces. The morphology of the CFRP plate does not change significantly.
- As the degree of corrosion damage increases, the ultimate load of CFRP–steel-bonded joints without GFS with the same bond length (30 mm) declines up to 16.51%, but the reduction rate slows down. The failure mode changes from CFRP delamination to steel–adhesive interface debonding with an increase in damage degree.
- The failure mode of joints with GFS is CFRP delamination for all corrosion damage categories except for CX, which exhibits steel–adhesive interface debonding. GFS in the adhesive layer can enhance the bond performance of the joints under corrosion conditions. Given a specific corrosion damage and bond length, the ultimate load of joints with GFS is greater than that of joints without GFS, with an increase of 8.26% for a very high corrosion damage level (C5).
- For joints with a very high level of corrosion damage (category C5), the ultimate load of the joints without GFS first increases and then remains constant (around 86 kN) as the bond length increases. The effective bond length of the corroded joint is about 130 mm, which is a little larger than the non-corroded joint. The failure mode is a mixture of CFRP delamination and steel–adhesive interface debonding, which is independent of the bond length.
- A bond–slip model is established for corroded CFRP–steel-bonded joints. The relationship is greatly affected by the corrosion damage, which has a much lower maximum interfacial shear stress (17.52 MPa), a smaller fracture energy (5.49 N/mm), and a progressive softening failing process.
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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| Properties | CFRP | Steel | Adhesive (Araldite 420) |
|---|---|---|---|
| Tensile strength (MPa) | 2659 | 539 | 30 |
| Yield strength (MPa) | N/A | 381 | N/A |
| Tensile modulus (GPa) | 155.9 | 219.6 | 1.744 |
| Group | Specimen Label | Bond Length (mm) | Corrosion Rate of Steel rcorr g/(m2·a) | Calculated Exposure Duration (s) |
|---|---|---|---|---|
| 1 | CF30-C0-1,2,3 | 30 | 0 | 0 |
| CF30-C2-1,2,3 | 200 | 3418.07 | ||
| CF30-C3-1,2,3 | 400 | 6836.14 | ||
| CF30-C4-1,2,3 | 650 | 11,108.72 | ||
| CF30-C5-1,2,3 | 1500 | 25,635.51 | ||
| CF30-CX-1,2,3 | 3000 | 51,271.02 | ||
| 2 | GF30-C0-1,2,3 | 30 | 0 | 0 |
| GF30-C2-1,2,3 | 200 | 3418.07 | ||
| GF30-C3-1,2,3 | 400 | 6836.14 | ||
| GF30-C4-1,2,3 | 650 | 11,108.72 | ||
| GF30-C5-1,2,3 | 1500 | 25,635.51 | ||
| GF30-CX-1,2,3 | 3000 | 51,271.02 | ||
| 3 | CF50-C5-1,2,3 | 50 | 1500 | 26,671.29 |
| CF70-C5-1,2,3 | 70 | 1500 | 27,707.07 | |
| CF90-C5-1,2,3 | 90 | 1500 | 28,742.84 | |
| CF110-C5-1,2,3 | 110 | 1500 | 29,778.62 | |
| CF130-C5-1,2,3 | 130 | 1500 | 30,814.40 | |
| CF150-C5-1,2,3 | 150 | 1500 | 31,850.18 |
| Category | Corrosivity | Corrosion Rate of Steel rcorr g/(m2·a) |
|---|---|---|
| C1 | Very Low | rcorr ≤ 10 |
| C2 | Low | 10 < rcorr ≤ 200 |
| C3 | Medium | 200 < rcorr ≤ 400 |
| C4 | High | 400 < rcor ≤ 650 |
| C5 | Very High | 650 < rcor ≤ 1500 |
| CX | Extreme | 1500 < rcorr ≤ 5500 |
| Group | Specimen Label | Measured Adhesive Thickness ta (mm) | Predicted Corrosion Mass Loss (g) | Measured Corrosion Mass Loss (g) | Ultimate Load Pult (kN) | Averaged Ultimate Load Pult.ave (kN) | Load Reduction (%) | Failure Mode |
|---|---|---|---|---|---|---|---|---|
| 1 | CF30-C0-1 | 0.39 | 0 | 0 | 50.87 | 50.32 | 0 | DL |
| CF30-C0-2 | 0.44 | 0 | 49.75 | DL | ||||
| CF30-C0-3 | 0.48 | 0 | 50.35 | DL | ||||
| CF30-C2-1 | 0.43 | 2.97 | 3.05 | 48.09 | 48.67 | 3.28 | DL + ID 1 | |
| CF30-C2-2 | 0.48 | 2.90 | 50.26 | DL + ID | ||||
| CF30-C2-3 | 0.41 | 2.65 | 47.65 | DL + ID | ||||
| CF30-C3-1 | 0.45 | 5.94 | 5.75 | 46.44 | 47.52 | 5.56 | DL + ID | |
| CF30-C3-2 | 0.42 | 5.8 | 48.09 | DL + ID | ||||
| CF30-C3-3 | 0.44 | 5.85 | 48.03 | DL + ID | ||||
| CF30-C4-1 | 0.41 | 9.65 | 9.45 | 47.63 | 46.27 | 8.05 | DL + ID | |
| CF30-C4-2 | 0.45 | 9.05 | 44.92 | DL + ID | ||||
| CF30-C4-3 | 0.40 | 9.65 | 46.19 | DL + ID | ||||
| CF30-C5-1 | 0.42 | 22.28 | 22.30 | 43.31 | 42.73 | 15.08 | ID + DL 2 | |
| CF30-C5-2 | 0.42 | 22.25 | 42.68 | ID + DL | ||||
| CF30-C5-3 | 0.39 | 22.25 | 42.20 | ID + DL | ||||
| CF30-CX-1 | 0.42 | 44.55 | 43.05 | 42.03 | 42.01 | 16.51 | ID + DL | |
| CF30-CX-2 | 0.48 | 44.75 | 41.31 | ID + DL | ||||
| CF30-CX-3 | 0.50 | 44.55 | 42.70 | ID + DL | ||||
| 2 | GF30-C0-1 | 0.43 | 0 | 0 | 49.23 | 49.22 | 0 | DL + GFS fragments |
| GF30-C0-2 | 0.42 | 0 | 50.28 | DL + GFS fragments | ||||
| GF30-C0-3 | 0.45 | 0 | 48.16 | DL + GFS fragments | ||||
| GF30-C2-1 | 0.48 | 2.97 | 2.90 | 48.11 | 47.90 | 2.68 | DL + ID | |
| GF30-C2-2 | 0.42 | 2.65 | 48.75 | DL + ID | ||||
| GF30-C2-3 | 0.50 | 2.95 | 46.85 | DL+ID | ||||
| GF30-C3-1 | 0.42 | 5.94 | 5.85 | 48.21 | 47.74 | 3.01 | DL + ID | |
| GF30-C3-2 | 0.47 | 5.85 | 47.55 | DL + ID | ||||
| GF30-C3-3 | 0.39 | 5.90 | 47.47 | DL + ID | ||||
| GF30-C4-1 | 0.41 | 9.65 | 9.75 | 46.37 | 47.58 | 3.33 | DL + ID | |
| GF30-C4-2 | 0.48 | 9.80 | 48.54 | DL + ID | ||||
| GF30-C4-3 | 0.46 | 9.60 | 47.83 | DL + ID | ||||
| GF30-C5-1 | 0.41 | 22.28 | 24.15 | 45.47 | 46.26 | 6.01 | DL + ID | |
| GF30-C5-2 | 0.49 | 22.15 | 46.17 | DL + ID | ||||
| GF30-C5-3 | 0.46 | 22.35 | 47.13 | DL + ID | ||||
| GF30-CX-1 | 0.42 | 44.55 | 44.10 | 43.12 | 42.57 | 13.51 | ID + DL | |
| GF30-CX-2 | 0.39 | 46.25 | 42.23 | ID + DL | ||||
| GF30-CX-3 | 0.46 | 44.35 | 42.35 | ID + DL | ||||
| 3 | CF50-C5-1 | 0.49 | 23.18 | 23.15 | 64.01 | 63.15 | 13.86 | DL + ID |
| CF50-C5-2 | 0.48 | 23.15 | 63.55 | DL + ID | ||||
| CF50-C5-3 | 0.42 | 23.15 | 61.88 | DL + ID | ||||
| CF70-C5-1 | 0.45 | 24.08 | 24.35 | 75.65 | 73.13 | 20.91 | DL + ID | |
| CF70-C5-2 | 0.46 | 24.50 | 73.31 | DL + ID | ||||
| CF70-C5-3 | 0.35 | 24.40 | 70.44 | DL + ID | ||||
| CF90-C5-1 | 0.50 | 24.98 | 25.25 | 80.96 | 83.67 | 20.89 | DL + ID | |
| CF90-C5-2 | 0.48 | 25.25 | 86.02 | DL + ID | ||||
| CF90-C5-3 | 0.39 | 25.05 | 84.02 | DL + ID | ||||
| CF110-C5-1 | 0.45 | 25.88 | 26.40 | 90.08 | 86.52 | 24.48 | DL + ID | |
| CF110-C5-2 | 0.40 | 26.25 | 82.17 | DL + ID | ||||
| CF110-C5-3 | 0.44 | 26.05 | 87.30 | DL + ID | ||||
| CF130-C5-1 | 0.46 | 26.78 | 27.15 | 86.65 | 87.46 | 27.27 | DL + ID | |
| CF130-C5-2 | 0.41 | 27.25 | 87.50 | DL + ID | ||||
| CF130-C5-3 | 0.48 | 27.35 | 88.23 | DL + ID | ||||
| CF150-C5-1 | 0.44 | 27.68 | 27.85 | 87.19 | 84.73 | 31.38 | DL + ID | |
| CF150-C5-2 | 0.48 | 27.75 | 81.62 | DL + ID | ||||
| CF150-C5-3 | 0.43 | 27.75 | 85.39 | DL + ID |
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Yu, Y.; Li, D.; He, L.; Tam, L.-H.; Wang, Z.; Wu, C. Corrosion-Induced Degradation Mechanisms and Bond–Slip Relationship of CFRP–Steel-Bonded Interfaces. Materials 2026, 19, 511. https://doi.org/10.3390/ma19030511
Yu Y, Li D, He L, Tam L-H, Wang Z, Wu C. Corrosion-Induced Degradation Mechanisms and Bond–Slip Relationship of CFRP–Steel-Bonded Interfaces. Materials. 2026; 19(3):511. https://doi.org/10.3390/ma19030511
Chicago/Turabian StyleYu, Yangzhe, Da Li, Li He, Lik-Ho Tam, Zhenzhou Wang, and Chao Wu. 2026. "Corrosion-Induced Degradation Mechanisms and Bond–Slip Relationship of CFRP–Steel-Bonded Interfaces" Materials 19, no. 3: 511. https://doi.org/10.3390/ma19030511
APA StyleYu, Y., Li, D., He, L., Tam, L.-H., Wang, Z., & Wu, C. (2026). Corrosion-Induced Degradation Mechanisms and Bond–Slip Relationship of CFRP–Steel-Bonded Interfaces. Materials, 19(3), 511. https://doi.org/10.3390/ma19030511

