Multiscale Study on the Bearing Performance and Failure of Interference‐Fit CFRP /Al Blind‐Riveted Joints

This study establishes a sequential multiscale numerical framework to investigate how interference affects the mechanical properties and damage behavior of single‐lap interference‐fit CFRP/Al blind‐riveted joints, with experimental validation through quasi‐static tensile tests and SEM observations. First, representative volume elements (RVEs) are constructed at the microscale, and a bottom‐up homogenization scheme calibrates the macroscopic elastic moduli of the laminates. A refined finite element (FE) model is then developed at the macroscale to characterize the load–displacement responses of the joints under various interference fit levels. Subsequently, a top‐down sequential framework is adopted to map the macroscopic strain histories extracted from selected hole‐edge elements onto the stochastic RVE model, enabling the evaluation of progressive damage mechanisms. This strategy balances high computational efficiency and mechanistic analysis of constituent‐scale failure modes. Macroscopic results indicate that moderate interference enhances the ultimate strength of the joint, whereas excessive interference induces preexisting damage on the hole wall and thus impairs the load‐bearing capacity. Microscopic observations reveal that microcracks preferentially nucleate in fiber‐rich, resin‐poor microregions, and the dominant failure modes depend on the local loading orientation.