A structural integrity approach has been applied to predict the safe operation of a hybrid adhesive bonded joint between a carbon fiber reinforced polymer and a magnesium light alloy. The joint is a structural part of a safety critical component, namely a smart wheel for a racing motorcycle. The influence of in-service loads on typical adhesive bonding defects is analyzed by finite element models and fracture mechanics concepts. Such an analysis has provided the needed targets for the ultrasonic inspection to be developed. The ultrasonic inspection was designed and validated experimentally by means of proper artificially defected lap joints and, then, performed on an actual smart wheel. A virtual inspection was performed, as well, by a proper computation for understanding the experimental results.

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