Fatigue resistance of an aluminium one-component polyurethane adhesive joint for the automotive industry: Effect of surface roughness and adhesive thickness (original) (raw)
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Journal of Advanced Joining Processes
Over the years, using adhesive joints in structural applications widespread all industrial domain, achieving an amazing current usage. This is due to the benefits that this technology is capable of providing to complex-shaped structures, both in aerospace and automotive applications. Indeed, new polyurethane adhesives are a recently fastening method. This newest adhesive types bid great advantages especially on damping, impact and fatigue which are critical characteristics in the transportation industry. Besides, the current bus manufactures use this adhesive kind to join doors' structures aluminium assembly. As like, the Tunisian automotive industry ICAR uses a one-component polyurethane for doors' structure assembly. Crack problems due to fatigue are evident in those areas since they are continuously stressed. Thereby, working on more understanding polyurethane fatigue performance we investigate over this work, the response of the assembly aluminium-alloy polyurethane adhesive joints using SLJ with two design's parameters sorted from a static study under five distinct load levels. To achieve this purpose, substrates' surfaces roughness with an arithmetic average of surface heights Ra ≈ 0.6 μm, was used. Bonded specimens with 1 mm adhesive thicknesses were manufactured and examined using cyclic fatigue testing. Furthermore, the obtained results are also compared with others from literature using epoxy adhesives. Worthy results are obtained rising the effectiveness of this adhesive's type in the transport industry.
Engineering Fracture Mechanics, 2017
The automotive industry is increasing, nowadays, its use of high performance structural adhesives in order to reduce vehicle weight and increase the crash resistance of automotive structures. One-component polyurethane adhesives are attracting rising interest as an alternative to conventional rigid structural adhesives. This is due to several benefits such as the excellent impact resistance they provide. This paper investigates experimentally the mechanical behavior of one-component polyurethane adhesive joints and specifically the effect of the adhesive layer to be used in several parts for buses structure. Furthermore, it characterizes the fracture behavior of the adhesive layer with various bond's thicknesses using mode-I and mode-II fracture testing. The fracture toughness under both modes is determined using Double Cantilever Beam (DCB) and End-Notched Flexure (ENF) tests, respectively. Assessment of the various fracture tests indicated that DCB and ENF provide the same shape of evolution of the fracture energy versus adhesive thickness. Moreover, the test results were able to fully mechanically characterize the adhesive and demonstrate that the adhesive has not only high mechanical strength but there is an optimal adhesive thickness, which allows a high toughness for bonded joints. This result proves that it is worthy to use the one-component polyurethane adhesive in the automotive industry.
A Review on Adhesively Bonded Aluminium Joints in the Automotive Industry
Metals
The introduction of adhesive bonding in the automotive industry is one of the key enabling technologies for the production of aluminium closures and all-aluminium car body structures. One of the main concerns limiting the use of adhesive joints is the durability of these system when exposed to service conditions. The present article primarily focuses on the different research works carried out for studying the effect of water, corrosive ions and external stresses on the performances of adhesively bonded joint structures. Water or moisture can affect the system by both modifying the adhesive properties or, more importantly, by causing failure at the substrate/adhesive interface. Ionic species can lead to the initiation and propagation of filiform corrosion and applied stresses can accelerate the detrimental effect of water or corrosion. Moreover, in this review the steps which the metal undergoes before being joined are described. It is shown how the metal preparation has an importan...
Fatigue De-bond Growth Study on Adhesively Bonded Single Lap Joints
The fatigue crack growth studies have been conducted on adhesively bonded joint specimens between aluminum-aluminum with Redux-319 A adhesive with a pre-defined crack of 3 mm at the bond end. The specimen dimensions are the same as given by ASTM for static strength evaluation . The correlations between fracture parameters and the de-bond growth data are established using both numerical and experimental techniques. In numerical method, finite element analyses are carried out on adhesively bonded joint specimen for various de-bond lengths measured from the lap end along mid-bond line of the adhesive (most of the times the failure is cohesive). The finite element results are post processed off-line to estimate the SERR components G I and G II using MVCCI procedure. In experimental work, specimens are fabricated and then tested under constant amplitude fatigue loading of 1kN and stress ratio (R) equal to -1. De-bond growth data: de-bond length (a) versus number of cycles (N) have been obtained. It is observed that the variation of G II with de-bond length is insignificant over the length. The de-bond growth rate is primarily function of mode-I SERR component G I . The results obtained from both numerical analyses and testing have been used to generate de-bond growth curve and establish de-bond growth law in the Paris regime for such joints. The value of Paris exponent m is found to be 6.55 for such joints with Redux 319 A adhesive. The high value of de-bond growth exponent in Paris regime is expected, since the adhesive is less ductile than conventional metallic materials. This study is important for estimating the life of adhesively bonded joints under both constant and variable amplitude fatigue load.
Design And Analysis Of Aluminium Adhesive Joints
2017
Adhesive bonding is widely used for sheet metal joining. Majority of automobile, aerospace parts, mainly their body components are joined together by different types of adhesives. So their growing demand needs the detailed study of strength analysis of adhesive joints. Investigation on single lap adhesive joint is to be done for various applications. Overlap length, load and Adhesive layer thickness has to be varied in the defined range & analysis is done by to see the nature of changes in the joint. FE analysis is done by using Ansys to observe the nature of changes in the joint. Validation by Mechanical testing is done by using Universal Testing Machine up to ultimate limit. Overall joint strength is related to maximum force that can be sustained by joint. The overlap at which the maximum force is required to break the joint is the length which can considered as optimum adhesive overlap length https://journalnx.com/journal-article/20150402
Evaluation of Fatigue Damage in Adhesive Bonding: Part 2: Single Lap Joint
2008
The damage parameters for crack initiation in a single lap joint (SLJ) are determined by combining continuous damage mechanics, finite element analysis (FEA) and experimental fatigue data. Even though a SLJ has a simple configuration, the stresses in the adhesive region are quite complex and exhibit multi-axial states. Such a condition leads to the need to introduce a general value for the triaxiality function in the damage evolution law rather than using a triaxiality function which equals unity, as in the case of a uni-axial stress state, e.g., the bulk adhesive test specimen presented in Part 1 of this paper. The effect of stress singularity, due to the presence of corners at edges, also contributes to the complex state of stress and to the variability of the triaxiality function along the adhesive layer in a SLJ. The damage parameters A and β determined in Part 1 for bulk adhesive are now extended to take into account the multi-axial stress state in the adhesive layer, as calculated from FEA.
Mechanics Based Design of Structures and Machines, 2020
Surface roughness obtained from different preparation processes such as sanding, shot blasting, and sand blasting were considered in this study. The effects of surface roughness on shear strength of single-lap adhesive joint were examined. 2024-T3 aluminum sheets were cut into standard pieces and then sanded with seven sandpapers with different mesh, shot blasted for four different duration times and sandblasted under four different pressures. Pairs of prepared surfaces were attached using Araldite 2015 adhesive with high viscosity and HPL1012/HPH112 epoxy adhesive with low viscosity. Results show that the ultimate lap shear strength of the sanded samples initially increase and then decrease as surface roughness is increased. The lap joint strength continuously increases as the surface roughness of shot blasted and sand blasted samples are increased. In sanding, the optimum surface roughness is different for both high and low viscosity adhesives. However, for shot blasting and sand blasting, the optimum surface roughness is the same for both adhesive types. The maximum ultimate lap shear strength of joints for both types of adhesives obtained for sand blasting under 0.6 MPa pressure with 0.6 lm surface roughness.
Experimental and numerical investigation of the effect of key joint variables on the static and fatigue performance of bonded metallic single-lap joints, In this paper, numerical and experimental methods are employed to investigate the effect of surface preparation, adhesive type and thickness, and nanoparticle enrichment on the mechanical performance of bonded metallic single-lap joints. Adherents are made of similar materials; namely, steel-on-steel or aluminum-on-aluminum. Investigated surface preparation variables include roughness and scratch orientation. Adhesive-related variables include thickness, type, and nanoparticle enrichment. Four different commercially available adhesives are investigated, some of which are nanoparticle enriched for the purpose of this study. Static and/or fatigue testing as well as damage analysis-based numerical prediction of joint performance, are provided. Scanning Electron Microscope (SEM) is used for macro joint characterization through the micro observation of joint fracture surfaces. Experimental fatigue data correlates reasonably well with the numerical results obtained from damage-coupled cohesive model of the adhesive layer.
Advances in Materials Science, 2021
The paper presents the results of experimental research aimed at determining the possibilities of strengthening structural adhesive joints. Techniques to improve the strength of adhesive joints was to make holes in the front part of the adherends in order to make the joint locally more flexible in the area of stress concentration at the joint edges. The tests were carried out for the lap joints of EN AW-2024-T3 aluminum alloy sheets, which were bonded with Loctite EA3430 epoxy adhesive. Static tests were carried out on the basis of the tensile/shear test. It has been shown that the applied structural modifications allow for an increase in the strength of the joint, in the best variant, an increase in strength of 14.5% was obtained. In addition, it has been shown that making holes in the adherends allows to reduce the spread of strength results.