A damage zone based failure criterion was experimentally and analytically verified using non-linear Finite Element Analysis (FEA) and was shown to work quite well in understanding the failure of the brazed joints. Excellent correlations were demonstrated between our predicted values and the experimental results published by other researchers for the same base/filler metal combinations. The same analysis were applied to the lap shear test specimens containing flaws deliberately introduced into the brazed joints. The results obtained showed good correlation between the experimental and calculated values and confirmed that the failure of the ductile lap shear brazed joints occurs when the damage zone reaches approximately 10% of the overlap width.
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