The application of paints and other coatings over joints, gaps, and fasteners is universal in industrial applications. Where substrate flexing occurs, such as in aerospace and automotive use, an understanding of strains within such systems is essential. Results of finite-element analysis of various two- and three-dimensional models of coated joints are presented here. We provide comparative strain concentration results assuming coatings of differing modulus, particularly showing regions where a high degree of strain control is possible. In two dimensions we examine results for a coated tensile joint, two-point bend with a notched trough, and two-point bend with separated substrate panels. In three dimensions, we provide results for an uncoated single panel containing a countersunk rivet.

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