Dissimilar Material Joints Research Articles

Mechanical and failure behaviors of adhesively bonded dissimilar materials joints incorporating bio-inspired morphological irregularities

Adhesive dissimilar material joints between stainless steel grade 316L and polyethylene terephthalate glycol (PETG) plastic were examined, in which irregular interface morphologies inspired by natural sutures were incorporated. The joint interfaces exhibited various teeth-like, non-repetitive zigzag patterns based on a pseudo-randomization method and sutural interdigitation index. Effects of their irregularities on mechanical and failure characteristics of adhesive butt joints were studied by means of experiments and FE simulations. The cohesive zone model, Drucker-Prager plasticity model and ductile failure criterion were applied for the interface and PETG, respectively. Predicted load-displacement curves of joints with different teeth profiles were well validated. The degree of irregularity became higher to 20 %, 40 %, and 60 %, the joint strengths decreased by 1.47 %, 5.39 %, and 11.95 %, while the total energies to failure increased by 110.74 %, 129.33 %, and 161.23 %, accordingly. More inhomogeneous morphologies led to earlier local damage initiation, but enhanced damage evolution range by impeding abrupt joint separation. Smaller teeth angles provided higher joint strength, whereas significant declines of bonding strength were observed by too acute teeth angle due to excessive stress localization and resulting teeth breakage. The teeth angle of 45° enabled the superior joint performance owing to a proper combination of interlocking and large adhesive force under shear stress state. Finally, a key insight for designing an optimal dissimilar joint with morphological irregularities was provided.

Microstructural characteristics and mechanical properties of laser-welded Ta10W/GH3030 joints with beam offset

Influences of the laser beam offset (LBO) on the microstructures as well as room-temperature and high-temperature mechanical properties of Ta10W/GH3030 dissimilar-material joints were investigated. In laser-welded Ta10W/GH3030 joints prepared under three conditions with LBOs of −0.2 mm (offset toward Ta10W), 0 mm, and + 0.2 mm (offset toward GH3030): the fusion zones (FZ) all contained expulsed substances Ni3Ta, NiTa, and Cr2Ta and their microhardness was certainly higher than the base metal (BM); a transition layer containing high contents of Ni3Ta, NiTa, and Cr2Ta phases was observed at the Ta10W/FZ interface. With the increase of the LBO, the contents of Ni3Ta, NiTa, and Cr2Ta in the FZ gradually declined, the average grain size in the FZ increased slightly, the microhardness of the FZ dropped rapidly, and the thickness of the transition layer at the Ta10W/FZ interface reduced obviously. Either in the room-temperature or high-temperature (750 °C) tensile tests, Ta10W/GH3030 joints were always fractured at the Ta10W/FZ interface, showing the typical brittle fracture mode, and the tensile strength of joints was enhanced with the increasing LBO. Under LBOs of −0.2, 0, and + 0.2 mm, the room-temperature tensile strengths of Ta10W/GH3030 dissimilar-material joints were 266.4, 308.6, and 341.2 MPa, while the high-temperature (750 °C) tensile strengths were 97.6, 191.5, and 202.7 MPa, respectively.

An experimental-cohesive zone model approach to predict fatigue life of adhesive joints with varying modes of loading and joint configurations for automotive applications

ABSTRACT Predictive fatigue life models of adhesive joints are necessary to enable the assessment of automotive-bonded structures while reducing costly experimental testing. However, contemporary models have typically been calibrated for specific joint configurations and modes of loading, limiting their applicability to large-scale structures. Additionally, available models are based on simulation of cumulative fatigue cycling, making them computationally prohibitive. In the current study, cross-tension (CT) (load angles of 0°, 45°, and 90°) and single-lap shear joint (SLJ) configurations were bonded using an epoxy adhesive (BetaGuard CI6125R; PPG, France) used in automotive production (one part) and tested under fatigue cyclic loading. A total of nine joint configurations, having symmetrical (same material and thickness) and asymmetrical (dissimilar material or unequal thickness) joints, were tested. Fatigue tests at load levels between 25% and 75% of the static peak load were performed until joint failure or to runout (two million load cycles). The static tests of the joints were simulated to failure using finite element (FE) models with the cohesive zone method (CZM). The maximum strain energy release rates ( G max ) were calculated within the adhesive bond line at static loads corresponding to the peak loads of the fatigue tests. The G max values, computed from single cycle, specimen-specific FE simulations, were correlated with the measured fatigue life ( N f ) of the adhesive joints with varying modes of loading and joint configurations. The fatigue life prediction model, based on G max − N f correlation and following a crack propagation approach, predicted the cycles to failure for 85% of the fatigue tests, and 81% of the independent validation tests. The proposed fatigue life prediction approach provides computational efficiency and large-scale compatibility.

Effect of energy on the interface morphologies and tensile-shear properties of the electromagnetic pulse welding T2/SS304 joints

This investigation focused on the effect that electromagnetic pulse welding (EMPW) of copper (T2) and stainless steel (SS304) dissimilar materials with various discharge energies, which is interfacial morphology and tensile-shear properties of the joints. The results showed that the interface of T2/SS304 dissimilar material joints treated with EMPW exhibits a typical waveform morphology. The maximum wave peak distance reaches 36 μm (39 kJ), and the distance between peak and trough reaches 6 μm (37 kJ, 39 kJ). The tensile-shear properties of the joints were better than those of the base material, with the fracture mode changing from interfacial fracture (35 kJ) to base mental fracture (37 kJ, 39 kJ), and the maximum tensile-shear of the joints was 11.1 kN (39 kJ). The wave spacing after fracture was extended up to 3 μm.

The influences of nanoparticles on the microstructure evolution mechanism and mechanical properties of laser welded stainless steel/aluminum

In order to solve the problem of poor performance of welded joints of steel and aluminum dissimilar materials, this study proposes the use of ceramic particle-reinforced aluminum alloy as an alternative to traditional aluminum alloy for welding, effectively overcoming this problem. In this paper, the laser welding of stainless steel/6061 aluminum alloy (SA) and stainless steel/TiC–TiB2 duplex nanoparticle-reinforced 6061 aluminum alloy (SRA) was realized. The effect of ceramic nanoparticles on the microstructure and mechanical properties of SRA joint was systematically studied, and the strengthening mechanism of nanoparticles was revealed. Under the same process parameters, the melting zone of SRA joint is larger and the intermetallic compound (IMCs) layer is narrower. Moreover, the grain size of the brittle Fe–Al compound phase in the IMCs layer is significantly reduced, which effectively inhibits the initiation of cracks at the steel/aluminum interface. The study shows that ceramic particles have a pinning effect on the dislocations, limiting the grain growth, reducing the thickness of the intermetallic compound layer, and decreasing the content of the brittle FeAl3 phase. Moreover, ceramic nanoparticles promote the formation of Mg2Si strengthened phase at the grain boundary, further hinder the dislocation movement and improve the strength of the joint. Under the welding power of 3400 W and welding speed of 31 mm/s, SRA joint achieves the maximum tensile shear of 1718 N, which is 15% higher than the strength of SA joint.

Effects of laminate stacking sequence on the strength properties of aluminum alloy–carbon fiber-reinforced plastic dissimilar single-lap adhesive joints

Here, two single-lap adhesive joints (SLJs) of dissimilar materials were subjected to static and cyclic loading tests. A2017 aluminum alloy was used as an adherend for one, and carbon fiber reinforced plastic (CFRP) was used as the adherend for the other. Four types of orthogonal laminated CFRPs with different laminate stacking sequences were used as adherends to investigate the effect of adherend stiffness on the strength properties of the joints. Furthermore, the results of the finite element analysis of the dissimilar SLJs revealed that when the tensile load was applied to them, the out-of-plane deformation asymmetry increased with increasing difference in stiffness between both adherends. This asymmetry affected the peel and shear stress distributions. Furthermore, the experiments revealed that the static tensile strength of the SLJs increased with increasing stiffness of the CFRP adherend. Additionally, fracture simulation using cohesive-zone modeling (CZM) revealed that the SLJs with higher CFRP stiffness exhibited higher strength, qualitatively agreeing with the experimental results. CZM analysis and adhesion strain measurements during the tests indicated that failure occurred at the A2017 adherend–adhesive interface. In contrast, no differences were observed between the fatigue strengths of the different types of adherends in the short-life region, with a number of cycles to failure (Nf) being ≤ 2 × 105. However, in the long-life region, beyond Nf = 2 × 105, the SLJ bearing the unidirectional CFRP adherend exhibited lower fatigue strength than the others. The anodizing process on A2017 was found to improve fatigue strength by a factor of two or more.

Stress Concentration Modelling on Resistance Spot Welding Lap Joint of Steel ASS316L and Titanium Ti-6Al-4V with Variable Weld Geometries

This research is a finite element simulation on resistance spot welding (RSW) process between dissimilar sheet metals consist of Titanium alloy, Ti-6Al-4V and Austenitic Stainless Steel (ASS) 316L. The problem statement was inability to visualize the stress concentration profile over weld nugget joint when Titanium alloy and steel welded with variable electrode geometry of circle, triangle, square and hexagon. To determine the best geometry for best weld with lowest maximum stress concentration. The methodology of simulation was tensile-shear test using SOLIDWORKS software. The tensile-stress load of 664.09 N was applied across all 4 different weld geometries. The result for the lowest magnitude of maximum stress 180.6 MPa was on circle weld geometry. Triangle geometry registered highest stress concentration of 219.6 MPa. This proves that most common weld geometry used in industry was circle. Even for dissimilar material joint the result supports that circle weld geometry as the best geometry. Keywords: Resistance spot welding (RSW), stress concentration, weld nugget, weld geometry.

Comprehensive investigation on linear friction welding a dissimilar material joint between Ti17(α+β) and Ti17(β): Microstructure evolution, failure mechanisms, with simultaneous optimization of tensile and fatigue properties

In order to advance the use of Ti17 (α+β)-Ti17(β) dissimilar material blisks produced with linear friction welding (LFW) for advanced aeroengines, detailed studies of failure mechanisms and performance enhancements of such joints were conducted. The changes in microstructure including phase transformations and dynamic recrystallization were investigated. Also, the tensile failure mechanism of the joint was investigated by in-situ tensile test using scanning electron microscopy, while the high-cycle fatigue failure mechanism was studied using quasi-in-situ electron back-scattering diffraction observations combined with transmission electron microscopy characterization. A post-weld annealing heat treatment (PWAHT) was applied for optimizing tensile and fatigue strength. Results shows that α dissolution and β continuous dynamic recrystallization (CDRX) are controlling microstructure changes during welding. Tensile loading failure is related to local dislocation slip concentration on the Ti17(β) side of the thermo-mechanically affected zone with limited α strengthening phase and low degree β CDRX; while fracture under high-cycle fatigue loading is related to equiaxed α/metastable β boundary microcracks on the Ti17 (α+β) side of the heat-affected zone, which was produced by unequal deformation between the two phases. Following PWAHT for 630 °C at 3 h, re-precipitation of secondary α occurred, which increased dislocation movement resistance in the weak areas, producing tensile and high-cycle fatigue strengths of 1196.4 MPa and 550.2 MPa, respectively, higher than those of BM-(β). In addition, an adequate plasticity of the joint with elongation of 8.7 % (82.1 % of Ti17(β)) was reached.

Laser welding of ultra-high strength steel rocket engine shell

The microstructure and mechanical properties of 30Cr3-30CrMnSiA ultra-high strength steel rocket engine shell welded joint were investigated in detail. The results indicated that the microstructure of the fusion zone was martensite of columnar and equiaxial due to the fast cooling rate of the laser welding. At the as-weld (AW) state, the average grain size of the 30Cr3 base metal was 4.63 μm, which was much smaller than that of the 30CrMnSiA base metal, which averaged 6.85 μm. After the post-weld heat treatment (PWHT), all the microstructures of the base metal, fusion zone and heat affected zone (HAZ) of 30Cr3 were tempered martensite. Meanwhile, at both AW and PWHT state, the tensile specimens of the welded joints of dissimilar materials were all fractured in the 30CrMnSiA base metal side at both 25 °C and 800 °C. After the PWHT, the tensile strength of 30CrMnSiA and 30Cr3 base metal at 25 °C were 1517.4 MPa and 1795.3 MPa, respectively. The welded joints of dissimilar materials by laser welding also showed excellent tensile properties at high temperature (800 °C), because of the small average grain size.

Design of dissimilar material joint for defect-free multi-material additive manufacturing via laser-directed energy deposition

Additive manufacturing technology has advanced beyond creating optimized features, from strengthening materials to make them lightweight to fabricating multi-material combinations that offer functionalities beyond the capabilities of individual materials. In this study, a lamination method for laser-directed energy deposition (LDED) is developed to achieve dense multi-material features, and a design that combines different and dissimilar materials is developed. To evaluate these novel developments, two materials—AISI 316L stainless steel and Inconel 625—are introduced. Tensile specimens, fabricated via multi-material additive manufacturing using LDED, are subjected to tensile tests that are recorded on video for digital image correlation. After the tests, fracture surface analyses of the fractured specimens are performed via scanning electron microscopy, and optical monitoring analyses are performed on the specimens that are not subjected to the tensile tests. The results indicate that the specimens demonstrate varied mechanical properties due to the influence of lamination direction and order, which affect the formation of critical cracks and pores.

THE EFFECT OF FRICTION TIME VARIATIONS ON DISSIMILAR MATERIAL WELDING JOINTS AND HARDNESS VALUE USING A BAR-PLATE ROTARY FRICTION WELDING MACHINE

This research aims to determine the effect of variations in friction time on welded joints of dissimilar materials and hardness values. The method used is the friction welding method. One of the materials widely used in industrial products is mild steel AISI 1037 and stainless steel 304. One of the tools used is a bar-plate upright rotary friction welding machine. The parameters used are friction time variations of 25-35 seconds, 55-65 seconds and 115-125 seconds with a rotational speed of 2,484 rpm, friction pressure of 0.5 MPa, forging pressure of 0.7 MPa, forging time of 10 seconds. From the results of the connection several tests were carried out, namely liquid penetrant , macro observation and hardness test. The results of liquid penetrant testing and macro observations showed no influence on the welding area. The results of hardness testing have an influence on the hardness value. In the interface area, the friction time variation of 120 seconds has the highest hardness value of 161.67 VHN. The lowest hardness value in the interface area with a friction time variation of 30 seconds is 152.90 VHN. Where the longer the friction time, the hardness value also increases.

Thermal cracking: Clarifying the effects of phases, voids and grains through characterisation and crystal plasticity modelling

Thermally-induced cracking typically occurs during the cooling stage of various manufacturing processes, and is commonly seen in multiphase or the joints of dissimilar materials due to mismatch in their thermo-mechanical properties, such as thermal expansion, elastic-plastic deformation and, in some cases, phase transformation. However, the underlying cracking mechanism associated with local microstructure is still elusive. To improve the mechanistic understanding of thermal cracking, this work uses the diffusion-bonded 9Cr-1Mo steel as an example to study the key microstructural variables, such as interfacial phases, voids, grain boundary migration and crystallographic orientations. Meanwhile, a temperature-dependent crystal plasticity model coupled with a cohesive zone model is developed to provide more insights into the thermal-induced stress distribution at the grain scale. It is found that the stress at the void-free boundary of martensite and ferrite is dominated by shear, and its magnitude is insufficient to nucleate cracks. Whereas voids at phase boundaries can induce significant tensile stress, resulting in cracking at the phase boundaries as well as diffusion-bonded interfaces. Also, the occurrence of interfacial grain boundary migration plays an important role in local stress distribution. These microstructure features and their evolution are experimentally observed and used to verify the developed crystal plasticity models. These findings enhance the understanding of the influence of microstructure features on thermal cracking and provide a guide to designing and fabricating the microstructure with improved thermal crack resistance in various manufacturing processes.

A novel in-situ forming 3D core-sheath interlayer designed to strengthen Cf/C composite-Nb joints during brazing

A novel interlayer designed to strengthen dissimilar material joints during brazing is reported in the current study. A highly elastic hollow carbon sponge was used as a consumable precursor to form a three-dimensional (3D) “metallic core-ceramic sheath” structure during the brazing of carbon-fiber-reinforced carbon matrix (Cf/C) composite /Nb with an Ag-Cu-Ti brazing filler. The brazing filler demonstrated excellent wetting properties on the sponge while simultaneously causing an in-situ reaction, producing a 3D interconnected and fine-grained TiC network shell filled with brazing filler as core due to capillary infiltration. The interlayer was shown to reduce residual stresses, prevent the formation of thick layered CuTi compounds, decrease the mismatch between the co-efficient of thermal expansion, and provide plastic strain accommodation. TGA, Raman, XRD and SAED were used to confirm various phase formations, locations and concentrations, and elucidate on the mechanism of formation. TEM and SEM were used for confirming microstructural properties and fracture morphology. Shear testing was conducted to confirm mechanical property increase, which was shown to be 260% above the baseline. The material and associated mechanism shown here are effective for the transmission and dissipation of shear loads and residual stresses, making it extremely attractive for high performance dissimilar material brazing.

Toward understanding the fractured mechanism in laser welded–brazed Al/steel interface by in–situ SEM tensile observations

In laser welded–brazed Al/steel dissimilar joints, interfacial metallic compound (IMC) had a determined effect on the joint strength. Dynamics interfacial fractured behaviors and generated condition for the IMC which was most beneficial for joint strength (aimed IMC) were hardly defined. This research investigated interfacial fractured behaviors for the joints obtained different laser manufacturing parameters (pure Al, AlSi5, AlSi12 filler metals and different laser powers). In−situ tensile SEM observations was adopted to provide a dynamics observation for the interfacial fractured behaviors. Then fractured behaviors for the joint obtained under coupling parameters of filler metals and laser powers were compared and summarized. It was discovered that aimed IMC was 2–3 µm τ5–Fe1.8Al7.2Si. Then numerical simulation was carried out to calculate the interfacial thermal cycles in order to define its generated thermal condition. Based on this, activity coefficient variations of Fe–Al–Si ternary system due to the addition of alloying element were calculated so as to define its generated metallurgy condition. Experimental results and numerical simulations proved that adding 12 wt% interfacial Si content, maintaining 968°C–1003 °C interfacial peak temperature and keeping 1.64–2.63 s time interaction at high temperature were the metallurgy and thermal conditions for the generation of 2–3 µm τ5–Fe1.8Al7.2Si. This research hoped to provide a reference for determination of interfacial regulation aim in other dissimilar materials joints.

Development of Hot Isostatic Pressing Technology for Joining Multiple Joints of Dissimilar Materials of Stainless Steels with IN 718 and Ti–6Al–4V

Development of Hot Isostatic Pressing Technology for Joining Multiple Joints of Dissimilar Materials of Stainless Steels with IN 718 and Ti–6Al–4V

Development of a Joint Concept for Producing Dissimilar Joints Using a 3D Printing-Supported Technique

The joining of metals and polymer-based materials has a very high interest for many industrial sectors, as it allows to achieve components combining the specific characteristics of each material class. Additive manufacturing technologies could boost the production of these joints, allowing the controlled deposition of a polymeric material over the metal substrate. The present research is aimed to study the feasibility of a joint concept that can be used to produce aluminium/polymer-based material joints through a 3D printing-supported technique. The innovative joint concept, which is based on an interlocking mechanism promoted by a deposited pin, was compared to two conventional concepts. The innovative joint concept allows the production of samples with good mechanical behaviour, in which the failure occurs outside the material overlapping zone. This design is very suitable to be tested for the production of dissimilar material joints.

Resistance rivet welding of multilayer dissimilar materials

Resistance rivet welding (RRW) process was applied to join three-sheet of Al/steel/steel. The formation mechanism, microstructure and mechanical performance of three-sheet dissimilar materials joints were studied in detail. The Al/steel/steel mixed nugget is produced by the fusion of Al/steel mixed and steel/steel nuggets. The microstructure of Al/steel/steel mixed nugget varies from mixed martensite and ferrite to full martensite as the increasing heat input. The ferrite contains numerous B2 structure nano-precipitates. The introduced Al element by the rivet cavity plays a significant influence on the microstructure, and the competition between ferrite and austenite stabilized elements in mixed nugget is responsible for the microstructure evolution. The phases performance of ferrite and martensite is determined. The average nano-hardness of ferrite is 2.66 GPa (271.3 HV), while that of martensite is 4.68 GPa (477.4 HV), and the yield strength for ferrite and martensite is calculated to be 475.0 MPa and 771.1 MPa, respectively. The average microhardness of the mixed nugget is 369.1 HV, 454.1 HV and 481.7 HV for welding parameters 7 kA-200 m s, 8 kA-200 m s and 9 kA-200 m s, presenting a trend of increasing with the heat input. Considering the multilayer joining containing both the Al/steel heterogeneous and steel/steel homogeneous interfaces, the comprehensive tensile-shear performance is optimal at welding parameters 8 kA-200 m s, 5334 N for Al/steel interface and 19,531 N for steel/steel interface.

Investigation of Microstructure and Mechanical Properties of Friction Stir Extruded Joints of Dissimilar Materials

Abstract The welding of steel and aluminum is difficult to join because of their differences in solid solubility, melting points, and formation of intermetallic compounds (IMCs), which may weaken the welded joints. Friction stir welding (FSW) has more feasibility for joining aluminum and mild steel (MS), but IMCs may form, affecting the joint properties. Friction stir extrusion (FSE) is a new derivative technique of FSW that reduces the tool wear and eliminates the formation of IMCs by forming mechanical interlocking joints at the interface. This present study applies the FSE process to join two dissimilar metals: Al6082 alloy and AISI 1020 MS. The FSE process is optimized by adjusting axial force, tool rotation rate, and traverse rate parameters. The mechanism of groove filling was observed and compared (at optimum parameters) with two different profile tools: one is a plain tapered tool and another is a tapered threaded tool; both were made of high-speed steel. The aluminum-MS joints were subjected to shear strength by conducting tension-shear tests using a dynamic servo-controlled fatigue testing machine, as per ASTM E466, Standard Practice for Conducting Force Controlled Constant Amplitude Axial Fatigue Tests of Metallic Materials. The hardness at the joint is evaluated by conducting Rockwell hardness tests, as per ASTM E18, Standard Test Methods for Rockwell Hardness of Metallic Materials. The microstructural characterization is done using optical electron microscope (OEM) and scanning electron microscope (SEM). The obtained results concluded that 30 mm/min is the optimum traverse rate for complete filling of the groove at 14.7-kN axial force and a tool rotation rate of 1,000 rpm. Furthermore, the discussions were made using hardness tests, OEM, SEM, and energy-dispersive spectroscopy analysis.

Analysis of laser welding on dissimilar materials with the influence of adding interlayer

The laser welding of dissimilar materials poses several challenges in practical applications, such as molten pool instability, the formation of intermetallic compounds (IMCs), and cracking caused by differential thermal stresses. In this study, we investigated the impact of incorporating a nickel (Ni) foil as an intermediate layer on lap joints of dissimilar materials (SS304 and Al6061) welded using the continuous laser welding (CLW) technique. The thermomechanical simulation accurately predicted the width and depth of SS304–Ni–Al6061 joints, with deviations of merely 3.92% and 19.04% from experimental results, respectively. Residual stress analysis revealed that the addition of a nickel foil reduced residual stress in the heat-affected zone (HAZ) and improved joint fatigue life. Furthermore, the incorporation of 0.1 and 0.2 mm Ni foils enhanced joint strength and effectively suppressed the formation of brittle intermetallic compounds, resulting in a remarkable maximum lap shear force of up to 1026 N. The simulation results for the shear load-displacement curve displayed excellent agreement with experimental data, with a deviation of only 6%. Notably, joints with the Ni foil demonstrated a greater ability to prevent crack formation caused by thermal expansion mismatch compared to joints without the Ni foil. The Ni interlayer served as a diffusion barrier and stress buffer, promoting a more uniform microstructure and reducing the likelihood of crack formation in bonded materials. Overall, this study comprehensively investigates the impact of incorporating a nickel interlayer on laser-welded lap joints of dissimilar materials. The findings offer valuable insights for practical applications, enabling improved joint strength, reliability, and crack resistance in laser welding dissimilar materials.

Indigenous Development of Epoxy Resin System for Cryogenic Services and Fusion Application

An epoxy resin system is used in a superconducting tokamak to insulate the conducting components, such as superconducting windings, cooling pipes, metal electrodes, and bonding and sealing of dissimilar material joints at cryogenic temperature. The main aim is to develop and fabricate the dissimilar material joints of metal and glass fiber reinforced plastic (GFRP) polymer in the form of cryogenic components for the superconducting fusion magnet. To bond and fabricate the dissimilar joints, the epoxy resin needs to have low viscosity, good adhesion, resistance to moisture, long usable life, and high toughness at low temperatures. A two-component-modified diglycidyl ether of bisphenol-A (DGEBA) epoxy resin was formulated with a modified polyamine-based hardener. To increase the toughness and minimize the induced thermal stress at low temperatures, a silane coupling agent, gamma-aminopropyltrithoxysilane, was used for its superior bonding and fast curing process. The tensile strength examination test results were found to 85 MPa, as per the International Organization for Standardization standard ISO 527-2, and an interlaminar shear strength of 12 MPa was found, as per the American Society for Testing and Materials standard ASTM D5868 at 77 K, respectively. The mechanical performance enhancements at 77 K overcome the issue of cracks and helium leaks that develop at cryogenic temperatures, as reported. The dissimilar material joints fabricated using the epoxy resin in the form of a cryo component have been validated in machine with an acceptable helium leak tightness of 1.0E-08 mbar-l/s. In this work, we report on the development, mechanical, thermal, and electrical performance tests, the testing and failures of various epoxy resins systems used, and the cryo components at 300 and 77 K.