Thermal Effects on Tensile Behavior of Composite–Metal Hybrid Bolted Joints: Experimental and Numerical Study Based on Micromechanical Failure Theory

Accurately predicting the mechanical response and failure of composite–metal hybrid bolted joints under thermo-mechanical coupled loads remains a critical challenge in aerospace engineering. This paper develops a temperature-dependent multi-scale progressive failure analysis model based on micromechanical failure theory. A hexagonal representative volume element (RVE) incorporating fibers, matrix and interphase is constructed, with a stress amplification factor enabling macro–meso stress–strain transformation. Dimensionless temperature corrections are applied to resin and interphase mechanical properties, and temperature-influenced mesoscopic failure criteria with corresponding stiffness degradation schemes are proposed. The nonlinear progressive damage simulation is implemented via the ABAQUS/UMAT subroutine. Static tensile tests on AC531/CCF800H composite-7075 aluminum alloy three-bolt double-shear joints are conducted at −70 °C, 20 °C and 120 °C. The results show excellent agreement between the simulations and experiments, with ultimate load errors < 5%. Low temperature increases load capacity by 3.91% via resin hardening and enhanced interfacial bonding, while high temperature reduces it by 9.07% due to resin softening. Failure modes shift from end-hole tensile fracture (−70 °C, 20 °C) to full-hole bearing failure (120 °C), governed by altered bolt load distribution and damage evolution paths. The proposed model provides reliable support for thermo-mechanical design and strength verification of aerospace composite structures.