Abstract: Based on three-dimensional progressive damage theory, the failure modes of the new metal-lap composite structure (consisting of aluminum alloy substrate and double CFRP composites reinforced structure) in the riveting, bonding and mixed connection form under the static load are investigated, respectively. Moreover, the influences of jointing parameters of this structure on the failure load are discussed. The results show that: The failure mode of rivet joint is shear failure of rivet. It is the failure of adhesive layer for the failure form of bonding. The hybrid joint was initially adhesive layer failure, and then overall failure due to shear failure of rivets. The failure load of the structure decreases first and then increases with the increase of the thickness of the up-adhesive, and increases first and then decreases with the increase of the thickness of the down-adhesive. As the bond width increases the failure load of the bond structure increases. When the bonding length increases, the failure load of the bond structure gradually increases first and then tends to be stable.

Key words: overlap structure, bonding, cohesive failure, failure load