Something to think about is the thermal expansion coefficient difference between the metal and carbon-fiber. Fab at room temp then curing at 120-135°C. Aircraft CF is 180°C but Spencer mentioned they used 137°C so WTF it wasn't Boeing old stock then? Surely CF for golf-clubs lol as Stockton no doubt skimped on the price/strength.
Then it gets used at 4°C in the ocean.
Carbon-fiber composite has a small -ve coefficient of thermal expansion (CTE), meaning as heated, it shrinks. The opposite of metals.
Toray carbon-fiber/
The differential stress during temp changes is close to nothing compared to the modulous of elasticity of TI being 16, steel is 29, Cf is around 40+, when they are placed under a 60,000 psi compressive load in the ocean.
Personally i would not be surprised they overlooked this, but if true then they could have been testing the, at best , 1500 psi bond of the epoxy to cf joint with each 4C to 25C thermal cycle.
Steel on steel produces about 29000 psi stress for every 180F or 100C temperature difference across equal area sections.
TI is just over half as stiff as steel but i dont know its expansion coefficient. You then have to multiply the expansion coefficient by the stiffness to get the stress, then solve some complex problems to get the sheer stress the joint is under.
The thickness of the epoxy also matters because the epoxy is so flexible compared to the CF or TI, it acts as a transition zone.
In fact its likely that the usual advice of "maximum strength is when the epoxy is at least .003" thick*" has nothing to do with any intrinsic difference in the epoxy but rather a joint of at least that thickness, smooths out the usual stress risers found in most everyday application and testing.
*And you can buy epoxy with glass beads in it to ensure that thickness.
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