Study of Degradation in Composite Lap Shear joints using a Guided Wave Technique

Experimental and numerical investigations were carried out using lamb waves to study the degradation in adhesive joints made of carbon fiber reinforced plastic (CFRP) adherends and epoxy adhesive. Degradation was inducted into the epoxy adhesive by adding different amounts of polyvinyl alcohol. Fundamental lamb wave modes were excited in the CFRP adherends using piezoelectric transducer disks and made to propagate through the adhesive layer. The received waveforms across adhesive joints with varied degradation were studied. A 2D finite element model was utilized to verify the experimental results. Good correlation was observed between numerical and experimental results. Details of the investigation and results obtained are presented in the paper.

Effect of temperature on the shear strength of aluminium single lap bonded joints for high temperature applications

An experimental and numerical investigation into the shear strength behaviour of adhesive single lap joints (SLJs) was carried out in order to understand the effect of temperature on the joint strength. The adherend material used for the experimental tests was an aluminium alloy in the form of thin sheets, and the adhesive used was a high-strength high temperature epoxy. Tensile tests as a function of temperature were performed and numerical predictions based on the use of a bilinear cohesive damage model were obtained. It is shown that at temperatures below Tg, the lap shear strength of SLJs increased, while at temperatures above Tg, a drastic drop in the lap shear strength was observed. Comparison between the experimental and numerical maximum loads representing the strength of the joints shows a reasonably good agreement.

Static shear strength and fatigue life of refill friction stir spot welded AA 6061-T6 sheets

This study was aimed at evaluating the static shear strength and fatigue properties of the newly developed refilled friction stir spot welded AA 6061-T6 joints. The keyhole, the process disadvantage of conventional friction stir spot welding, was refilled successfully, using an additional filler plate, with specially designed tools. Two different tool profiles, namely, convex and concave, were used for the refilling process. Sound and defect free joints were obtained by the refilling process. Joints refilled with convex tools showed better static shear strength than those with the concave ones. The variation of microhardness in different regions of the weld was analysed. Fatigue tests were conducted on the lap shear specimens at a stress ratio of R=0.1. The optical micrographs of the welds after fatigue failure in both the conventional and refilled processes were examined to study the fatigue crack propagation and failure modes.

Shear strength of adhesively bonded polyolefins with minimal surface preparation

Interest in polyethylene and polypropylene bonding has increased in the last years. However, adhesive joints with adherends which are of low surface energy and which are chemically inert present several difficulties. Generally, their high degree of chemical resistance to solvents and dissimilar solubility parameters limit the usefulness of solvent bonding as a viable assembly technique. One successful approach to adhesive bonding of these materials involves proper selection of surface pre-treatment prior to bonding. With the correct pre-treatment it is possible to glue these materials with one or more of several adhesives required by the applications involved. A second approach is the use of adhesives without surface pre-treatment, such as hot melts, high tack pressure-sensitive adhesives, solvent-based specialty adhesives and, more recently, structural acrylic adhesives as such 3M DP-8005® and Loctite 3030®. In this paper, the shear strengths of two acrylic adhesives were evaluated using the lap shear test method ASTM D3163 and the block shear test method ASTM D4501. Two different industrial polyolefins (polyethylene and polypropylene) were used for adherends. However, the focus of this study was to measure the shear strength of polyethylene joints with acrylic adhesives. The effect of abrasion was also studied. Some test specimens were manually abraded using 180 and 320 grade abrasive paper. An additional goal of this work was to examine the effect of temperature and moisture on mechanical strength of adhesive joints.

Effect of hole drilling at the overlap on the strength of single-lap joints

Bonded unions are gaining importance in many fields of manufacturing owing to a significant number of advantages to the traditional fastening, riveting, bolting and welding techniques. Between the available bonding configurations, the single-lap joint is the most commonly used and studied by the scientific community due to its simplicity, although it endures significant bending due to the non-collinear load path, which negatively affects its load bearing capabilities. The use of material or geometric changes in single-lap joints is widely documented in the literature to reduce this handicap, acting by reduction of peel and shear peak stresses at the damage initiation sites in structures or alterations of the failure mechanism emerging from local modifications. In this work, the effect of hole drilling at the overlap on the strength of single-lap joints was analyzed experimentally with two main purposes: (1) to check whether or not the anchorage effect of the adhesive within the holes is more preponderant than the stress concentrations near the holes, arising from the sharp edges, and modification of the joints straining behaviour (strength improvement or reduction, respectively) and (2) picturing a real scenario on which the components to be bonded are modified by some external factor (e.g. retrofitting of decaying/old-fashioned fastened unions). Tests were made with two adhesives (a brittle and a ductile one) varying the adherend thickness and the number, layout and diameter of the holes. Experimental testing showed that the joints strength never increases from the un-modified condition, showing a varying degree of weakening, depending on the selected adhesive and hole drilling configuration.

Numerical prediction of load-displacement behaviors of adhesively bonded joints at different extension rates and temperatures

The present work focuses on simulation of nonlinear mechanical behaviors of adhesively bonded DLS (double lap shear) joints for variable extension rates and temperatures using the implicit ABAQUS solver. Load-displacement curves of DLS joints at nine combinations of extension rates and environmental temperatures are initially obtained by conducting tensile tests in a UTM. The joint specimens are made from dual phase (DP) steel coupons bonded with a rubber-toughened adhesive. It is shown that the shell-solid model of a DLS joint, in which substrates are modeled with shell elements and adhesive with solid elements, can effectively predict the mechanical behavior of the joint. Exponent Drucker-Prager or Von Mises yield criterion together with nonlinear isotropic hardening is used for the simulation of DLS joint tests. It has been found that at a low temperature (-20 degrees C), both Von Mises and exponent Drucker-Prager criteria give close prediction of experimental load-extension curves. However. at a high temperature (82 degrees C), Von Mises condition tends to yield a perceptibly softer joint behavior, while the corresponding response obtained using exponent Drucker-Prager criterion is much closer to the experimental load-displacement curve.

Non-destructive evaluation of porosity and its effect on mechanical properties of carbon fiber reinforced polymer composite materials

Structural adhesive bonding is widely used to execute assemblies in automobile and aerospace structures. The quality and reliability of these bonded joints must be ensured during service. In this context non destructive evaluation of these bonded structures play an important role. Evaluation of adhesively bonded composite single lap shear joints has been attempted through experimental approach. Series of tests, non-destructive as well as destructive were performed on different sets of carbon fiber reinforced polymer (CFRP) composite lap joint specimens with varied bond quality. Details of the experimental investigations carried out and the outcome are presented in this paper.

Failure modes and fatigue behavior of conventional and refilled friction stir spot welds in AA 6061-T6 sheets

The fatigue behavior of conventional friction stir spot welding (FSSW) and friction stir spot welding refilled by the friction forming process (FSSW-FFP) in aluminum 6061-T6 lap shear specimens, are investigated based on the experimental observations. Optical micrographs of the welds after fatigue failure in both the cases are examined to study the fatigue crack propagation and failure modes. Experimental results indicate that the fatigue strength of the FSSW-FFP weld samples is higher than that of the conventional FSSW samples at all loads. Fracture surfaces are analyzed in detail using the scanning electron microscope. (C) 2013 Elsevier Ltd. All rights reserved.

Epoxy composites containing cobalt(II)-porphine anchored multiwalled carbon nanotubes as thin electromagnetic interference shields, adhesives and coatings

Herein a facile strategy has been adopted to design epoxy based adhesive/coating materials that can shield electromagnetic radiation. Multiwalled carbon nanotubes (MWNTs) were non-covalently modified with an ionic liquid and 5,10,15,20-tetrakis(4-methoxyphenyl)-21H,23H-porphine cobalt(II) (Co-TPP). The dispersion state of modified MWNTs in the composites was assessed using a scanning electron microscope. The electrical conductivity of the composites was improved with the addition of IL and Co-TPP. The shielding effectiveness was studied as a function of thickness and intriguingly, composites with as thin as 0.5 mm thickness were observed to reflect 497% of the incoming radiation. Carbon fibre reinforced polymer substrates were used to demonstrate the adhesive properties of the designed epoxy composites. Although, the shielding effectiveness of epoxy/MWNT composites with or without IL and Co-TPP is nearly the same for 0.5 mm thick samples, the lap shear test under tensile loading revealed an extraordinary adhesive bond strength for the epoxy/IL-MWNT/Co-TPP composites in contrast to neat epoxy. For instance, the lap shear strength of epoxy/IL-MWNT/Co-TPP composites was enhanced by 100% as compared to neat epoxy. Furthermore, the composites were thermally stable for practical utility in electronic applications as inferred from thermogravimetric analysis.

The Use of Carboxy Terminated Liquid Natural Rubber (CTNR) as an Adhesive in Bonding Rubber to Rigid and Non-rigid Substrates

Carboxy Terminated Liquid Natural Rubber (CTNR) was prepared by photochemical reaction using maleic anhydride and masticated natural rubber (NR). The use of CTNR as an adhesive in bonding rubber to rubber and rubber to metal was studied. The peel strengths and lap shear strengths of the adherends which were bonded using CTNR were determined. The effect of using a tri isocyanate with CTNR in rubber to metal bonding was also studied. It is found that CTNR can effectively be used in bonding rubber to rubber and rubber to mild steel.

Rubber Solution Adhesives for Wood-to-Wood Bonding

Rubber solutions were prepared and used for bonding wood pieces. The effect of the variation of chlorinated natural rubber (CNR) and phenolformaldehyde (PF) resin in the adhesive solutions on lap shear strength was determined. Natural rubber and neoprene-based adhesive solutions were compared for their lap shear strength. The storage stability of the adhesive prepared was determined. The change in lap shear strength before and after being placed in cold water, hot water, acid, and alkali was tested. The bonding character of these adhesives was compared with different commercially available solution adhesives. The room-temperature aging resistance of wood joints was also determined. In all the studies, the adhesive prepared in the laboratory was found to be superior compared to the commercial adhesives.

Melding: a new alternative to adhesive bonding

Melding, a novel method for joining composites is examined in this paper. The method uses Quickstep ™ technology to retain partially cured areas of a composite laminate, enabling subsequent bonding operations. The effect of melding on the mechanical properties of the composite has been investigated. Flexural testing of HexPly 914 indicates consistent properties throughout a melded section. Flexural strength values of 1.36±O.03 GPa compared to 1.35±O.03 GPa for a standard laminate were recorded. In order to achieve sufficient bond strength, the portion of the composite to be joined must have a significant proportion of uncured matrix. The ability of Hexply 914 prepreg to retain sufficient bonding potential to form a strong joint was also investigated. HexPly 914 Lap Shear results indicated no significant variation in strength values between co-cured and melded joins, with a recorded
strength value of 15.0±0. 7 MPa.

Modelling of laser beam spot-weld using 2-D hybrid crack finite elements

Laser beam spot-welding is widely applied to join sheet metals for automotive components especially for thinsheet components in automotive industries. The spot welds in such metallic structures contribute a lot to the integrated strength and fatigue life for the whole structures and they are responsible for their damage or collapse in some loading cases. In this paper, the 2-D hybrid special finite elements each containing an edge crack are employed to study the fracture behaviors of laser beam spot-welds. Hence the calculation accuracy in the vicinity of crack tips is ensured, and a better description of stress singularity with only one hybrid element surrounding one crack is provided. The numerical modeling for laser beam spot-welds subjected to three typical modes ofloadings including tension-lap, shear-lap and angle-clip can be greatly simplified with the applications of such elements. Three specimens under lap-shear, lap-tension and angle clip are devised and analyzed respectively, and main fracture parameters such as stress intensity factors and the initial direction of crack growth are obtained through tinite element analyses. The computed results ti'om numerical examples demonstrate the validity and versatility of the proposed modeling.

Fracture analysis of spot-welds with edge cracks using 2-D hybrid special finite element

This paper employed a systematic analysis using a 2-D hybrid special finite element containing an edge crack in order to describe the fracture behavior of spot-welds in automotive structures. The 2-D hybrid special finite element is derived form a mixed formulation with a complex potential function with the description of the singularity of a stress field. The hybrid special finite element containing an edge crack can give a better description of its singularity with only one hybrid element surrounding one crack. The advantage of this special element is that it can greatly simplify the numerical modeling of the spot welds. Some numerical examples demonstrate the validity and versatility of the present analysis method. The lap-shear, lap-tension and angle-clip specimens are analyzed and some useful fracture parameters such as the stress intensity factor and the initial direction of crack growth are obtained simultaneously.

Experimental investigation on bonding properties of reactive liquid rubber epoxy in CFRP retrofitted concretet members

The load bearing capacity of aging reinforced concrete structures, such as bridges, is increasingly extended with the use of Carbon Fibre Reinforced Polymer (CFRP). Premature failure, which is attributed to the rigid behaviour of the bonding agent (epoxy resin) and the high stresses at the interface region, can occur because of the debonding of CFRP sheets from host surfaces. To overcome the debonding issue, the epoxy resin is modified by different reactive liquid polymers to improve its toughness, flexibility, adhesion, and impact resistance. This study reports the usage of two reactive liquid polymers, namely, liquid Carboxyl-Terminated Butadiene-Acrylonitrile (CTBN) and liquid Amine-Terminated Butadiene-Acrylonitrile (ATBN), to improve the mechanical properties of the commercially available MBrace saturant resin when added to a ratio of 100:30 by weight. The neat and modified epoxies were analysed using the Dynamic Mechanical Thermal Analysis (DMTA) to determine and compare the storage modulus and glass transition temperatures of these materials. Moreover, the bonding strength of neat and modified epoxies was evaluated through single-lap shear tests on CFRP sheets bonded to concrete prisms. The results indicate that the modified resins exhibited improved ductility and toughness and became reasonably flexible compared with the neat epoxy resin. The improved properties will help delay the premature debonding failure in CFRP retrofitted concrete members.