The accurate calculation of the stresses and torque capacities of the adhesive bonded joints is not possible without understanding of the failure phenomena of the adhesive joints and the nonlinear behavior of the adhesive. In this paper, the adhesive failure model of the adhesive bonded tubular single lap joint with steel-steel adherends was proposed to predict the torque capacity accurately. The model incorporated the nonlinear behavior of the adhesive and the different failure modes in which the adhesive failure mode changed from the bulk shear failure. via the transient failure. to the interracial failure between the adhesive and the adherend, according to the magnitudes of the fabrication thermal residual stresses.