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Interference-fit is attracting increasing attention in the aerospace field because of its excellent enhancement of the sealing and fatigue life of carbon fiber reinforced plastic (CFRP). However, it also induces imbalanced pre-tightening forces on the interface, and affects its mechanical behavior. A series of experiments were conducted to assess the imbalanced pre-tightening force of CFRP interference bolted joints and its effects. High-precision washer force sensors were used to measure the pre-tightening force between upper and lower surfaces at various interference-fit and torque. Strain gauges were used to estimate the varying effect on the imbalanced pre-tightening force during tensile tests. The effects of varying interference-fit and torque on pre-loaded transfer, surface strain distribution, tensile strength, and damage mode were identified. The results show that the synergy of interference-fit and torque induces an imbalanced pre-tightening force, which, in turn, changes the stress-strain evolution of the surface, and a special “transition regime” was identified in the evolution curves. Compared with clearance-fit, the ultimate strength and optimal torque of interference-fit joints could be significantly enhanced. In addition, the damage originates from fiber/matrix slipping to the upper surface with a low pre-tightening force and the formation of stack buckling, which then causes delamination fracture.

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