Shear Strength Of Joints Research Articles

Torsional shear strength of adhesive joined steel in saline environments

This study investigates the impact of exposure to aggressive environments, specifically saline conditions per ASTM B117 standard, on the shear strength of adhesive‐bonded joints, crucial for ensuring structural integrity in various industrial applications like automotive, aerospace, and construction. Employing an epoxy‐based adhesive to bond AISI304 steel, specimens undergo 14‐ and 28‐day salt spray treatments to simulate harsh working conditions. Torsional shear strength assessment of steel‐to‐steel adhesive joints is conducted using a torsion test methodology, with an analytical approach used to extrapolate adhesive joint shear strength. This research contributes to understanding adhesively bonded joint performance in challenging environmental conditions, and how the shear strength of the bonded joints changes in relatively small amount of time, offering valuable insights for robust structural designs across industrial sectors.This article is protected by copyright. All rights reserved.

Enhancing shear strength of single lap composite adhesive joint with graphene nano-particles and Z-pins reinforcement through co-curing technique

Glass fiber-reinforced polymer (GFRP) co-cured (CC) single lap joint (SLJ) adhesive specimens with varying weight percentages (wt%) of graphene nanoparticles (GNP) and different volume percentages (vol%) of carbon fiber-reinforced polymer (CFRP)Z-Pin went through a shear test, and the results showed that 0.75 wt% GNP and 2.5 vol% 90°/Z-Pin reinforced specimens exhibited higher shear strength. Optimised GNP% and vol% of Z-Pin applied to SLJ showed high shear strength. The study was further compared with SLJ incorporating 0.75 wt% GNP with a 45°/Z-Pin specimen, and the results showed that the optimised 0.75 GNP% and 2.5 vol% 90°/Z-Pin SLJ specimen showed higher shear strength. After testing, microscopic images of the fractured specimen surface were taken to examine the failures. Fractography shows that adding GNP and Z pin to SLJ roughens surfaces, improving adhesive-adherent interaction.

Modulation of Co-depleted zone and shear strength of YG18/40Cr joints by pre-plated Co layer on YG18 surface

The multi-layer composite filler metal (YG18 surface pre-plated with Co layer + Ag–Cu–In–Ti filler metal) was designed in this study. The mechanism of modulation of Co-depleted zone and shear strength of joints by Co plating was elucidated. A more significant Co-rich layer existed around the WC particles, meanwhile, the presence of plastical Ag–Cu–In ternary eutectic between the TiCo layer and the YG18/TiC layer relieved the joint stress and ensured that no cracks were generated in the TiCo layer. Under the condition that the width of the Co-depleted zone was smaller (less than 3 μm), the presence of the dispersed Ti2Cu particles surrounded by the plastic phases ternary eutectic and Cu [s, s] in the filler layer was superior in terms of preventing crack propagation and absorbing the stress concentration. The best modulation of the filler layer microstructure and the Co-depleted zone was achieved when the pre-plated Co layer was around 2.5 μm. The Co-depleted zone was reduced by 50%, and the shear strength of joints was increased by 49% to 291 MPa. The results of the study provide a new way to design new multilayer composite filler metal.

Bond-slip model of headed bar and its application to component-based model for precast concrete joints under accidental loads

This study focused on investigating bond-slip behaviour of headed bars embedded in well-confined concrete. Test results based on eight pull-out specimens under displacement-controlled incremental loading showed that recommended development lengths from ACI318–19 are conservative in developing ultimate strength of headed bars associated with smaller slips than straight bars. Moreover, it was found that different (but sufficiently long) embedment lengths had a significant effect on the free-end slip but negligible effect on the loaded-end slip of headed bars. Additionally, the study highlighted the significance of head bearing in anchorage formation, especially during inelastic stage when bond strength had deteriorated. To address inaccuracy in predicting structural behaviour caused by inadequate anchorage strength of headed bars, a macro bond-slip model was proposed based on correlation in strain distribution obtained from the pull-out tests. Subsequently, the proposed model was incorporated into a component-based model (CBM) and validated against test results of PC joints under seismic loading. A numerical investigation using the validated CBM was conducted to study behaviour of exterior PC joints with headed bars and special detailing. These included Type X joint with X-bent bars and plastic hinge relocation (PHR), and Type A joint with an additional bar layer (ABL) in the beam-joint region, subjected to extreme loads such as seismic action or progressive collapse. The results revealed that seismic behaviour of exterior joints was governed by ductile failure of the beam at the PHR and vertical joint interface in Type X and Type A joints, respectively. Progressive collapse was primarily caused by column failure, with flexural and catenary action effectively preventing collapse. Notably, under both loading conditions, presence of ABL in Type A joint and X-bent bars with PHR in Type X joint improves flexural strength of beams at critical sections and joint shear strength, ultimately enhancing structural performance of joints. Design recommendations include replacing hooked bars with headed bars as well as implementing X-bent bars with PHR and ABL in PC joints. The authors advocate the strong-column-weak-beam design approach as an effective measure to prevent progressive collapse.

Study on the effect of anti-oxidation film formed by composite system on solder balls performance

In this paper, an anti-oxidation film was formed on the surface of Sn3.0Ag0.5Cu solder balls by using a composite system of benzotriazole (BTA) and 2-aminobenzimidazole (2-ABT). The properties of anti-oxidation film were measured by shaking balls test, shearing strength test and cavity test. The results showed that when the combination of 1.5 g/L BTA and 0.5 g/L 2-ABT was used to form an anti-oxidation film on the surface of solder balls, the life of the solder balls surface without dendrite wear during shaking balls test was increased by 10 times, and the cavity rate was decreased from 5 % to 3 %, resulting in that the shear strength of the solder joint was increased from 20.96 MPa to 40.45 MPa. And the theoretical calculation results showed that N2 atoms of benzotriazole and 2-aminobenzimidazole molecules were the most active and adsorbed on the surface of the solder balls to form anti-oxidation films.

Determining the optimal sampling interval for 3D morphology measurements of different-sized natural rock joints

Efficiently studying the scale effect of surface roughness and peak shear strength of natural rock joints, especially unfilled and well-matched ones, requires an optimal sampling interval to realize cost-effective three-dimensional morphology measurements for different-sized natural rock joints with advanced non-contact optical devices. However, rationally determining such an optimal sampling interval remains controversial. To this end, inspired by digital signal processing, the optimal sampling interval is creatively determined by Shannon's sampling theorem using the Fourier series' optimum order. An empirical formula relating the joint size to the optimum order is correspondingly developed. The proposed empirical formula was found to work well under conditions of high normal stress, where the relative errors for the surface roughness and peak shear strength of series-sized natural rock joints were mostly less than 10% and 5%, respectively, but should be used cautiously under conditions of low normal stress. Furthermore, different from previous perceptions, a higher joint roughness level was discovered to not necessarily imply the need for a smaller optimal sampling interval, and conversely. The proposed empirical formula can facilitate the determination of the optimal sampling interval for measuring different-sized natural rock joints' surface morphologies in engineering practice.

Experimental study on exterior precast concrete beam-to-CECFST column joints with wet connections under cyclic loading

Concrete-encased concrete-filled steel tube (CECFST) structural system has gained popularity in recent years due to its several advantages over conventional structures. Additionally, precast technology has become an effective way of improving construction efficiency and environmental performance. Therefore, it is essential to investigate the structural behaviour of precast concrete (PC) beam-to-CECFST column joints to ensure their optimal performance in applications. In this regard, this paper presents an experimental study of 4 precast exterior joints subjected to lateral cyclic loading. The study investigated the effect of replacing normal concrete with steel fibre-reinforced concrete at the joint region and the presence of axial load on PC composite joints. Based on the test results, cyclic load-carrying resistance, failure modes and crack patterns of the PC specimens were recorded and analysed. In addition, a Digital Image Correlation (DIC) system was adopted to show the crack evolution of joint specimens and calculate shear strains of concrete encasement at the joint region. Further comparisons were conducted in terms of ductility, energy dissipation, stiffness and strength degradation to investigate the joint performance. Finally, existing American and European design code provisions were modified and used to predict joint shear strength. Their predictions were reasonably close to the test results.

Low-frequency vibration assisted self-pierce riveting (LV-SPR) of carbon fiber reinforced composite and aluminum alloy

Self-pierce riveting (SPR) has been widely applied to join carbon fiber-reinforced polymer (CFRP) composites and high-strength metallic plates in the automotive and aerospace fields. However, the CFRP is often damaged by rivet piercing owing to its brittleness as well as the relatively small interlocking that forms between the rivet leg and high-strength plate owing to the hard deformation characteristics. Therefore, in this study, a novel low-frequency vibration-assisted self-pierce riveting (LV-SPR) technology is proposed, which utilizes the vibration effect in softening the metal and reducing interfacial friction at room temperature. In riveting experiments involving CFRP and 5052 aluminum alloy utilizing 37Cr4 semi-hollow rivets, LV-SPR exhibited a significant reduction of 68.2% in the riveting force compared to the traditional SPR process. The decreased riveting pressure in LV-SPR effectively mitigated the CFRP damage by 36.2%, which was caused by a reduction in the interfacial friction force between the rivet and CFRP laminate. Moreover, owing to the improved deformation capacity of the rivet and alloy plate by the vibration softening effect, the lateral expansion of the rivet leg in the aluminum alloy was enlarged by 36.4% compared to that using the traditional self-piercing riveting (T-SPR) process. Microscopic characterization revealed that vibrations notably promoted grain refinement and enlarged the subgrain structures of the rivets and alloy plates. Finally, by superposing oscillations, the shear strength of the connection joint increased by 13.5% compared to the T-SPR joint. The proposed LV-SPR was validated as an effective technique to increase the connection strength of high-performance plates, which can efficiently improve the structural safety and promote the widespread application of CFRP/alloys in automobiles and aircrafts.

Effects of a nickel-based alloy interlayer on electrically assisted pressure joining of pure titanium and stainless steel 304

This study focuses on the solid-state joining of commercially pure titanium (CP-Ti) and stainless steel 304 (SUS304) using electrically assisted pressure joining. A nickel-based alloy foil acting as an intermediate layer (Ni interlayer) is inserted between two base materials during joining to avoid the formation of a detrimental TiFe intermetallic due to direct contact of the CP-Ti and SUS304. The solid-state joining process can be completed within 2 s. The effectiveness of incorporating the Ni interlayer on joint quality is systematically investigated by comparing joints made with and without the use of a Ni interlayer. Microstructure analysis reveals that the Ni interlayer plays a critical role in improving joint quality by forming a nanocrystal structure and preventing the formation of TiFe intermetallic. Furthermore, the joint with a Ni interlayer increases the joint shear strength by at least 50% more than a joint without a Ni interlayer in the same joining period and exhibits tensile ductile fracture at the heat-affected zone in the CP-Ti side during tension. The present study provides valuable insights into the benefits of Ni interlayers in the rapid and reliable creation of solid-state joints between CP-Ti and SUS304 using electrically assisted pressure joining.

Comparing the Solderability of Different SA C0307 Composite Solder Pastes

In the present study, the effect of four oxide ceramics (TiO2, ZnO, ZrO2, and CuO) as reinforcements were investigated on the soldering parameters of the SAC 0307 solder alloy. The oxide ceramics were used in nano-powder format. Composite solder pastes were composed by the standard ball milling process of the nano-particles into the SAC 0307 solder paste in 0.25wt% weight fraction. The wettability, shear strength, and microstructure of the composite solder joints were studied and compared. The ceramic nano-particles did not have a major effect on the wettability of the solder. Shear strength increases were observed at the composite joints, except in the case of ZnO. Generally, Sn grain refinement was found in the Sn-matrix which could be the reason for the shear strength increase.

Effect of laser micromachining crater-array–multi-grooves on the bonding strength and failure mode of aluminum alloy adhesive joints

The strength of aluminium (Al) alloy adhesive joints is essential for aerospace, ship and automotive applications. This study proposes the two-step laser processing of crater-array–multi-groove (CAMG) to maximize the shear strength of adhesive joints for 7075-T6 aluminum alloys. Firstly, the effects of CAMG feature parameters (groove pattern, groove spacing L, and groove depth Gp) on the surface roughness (Sa), shear strength (τ), and microscale failure mode were studied. The failure mode and anchoring structure reveal the influence mechanism of CAMG feature parameters on τ. Then, the parameters are optimized to obtain the best combination that maximizes τ. Finally, the advantages of CAMG were demonstrated by comparing it with a reference specimen and analyzing the surface morphology, wettability, chemical properties, and anchorage structure. The results show that for CAMG the surface had high cleanliness, wettability, and chemical modifications. The multi-scale anchoring structure formed by the grooves, craters, and micropores on the surfaces with the adhesive was sufficiently strong to allow cohesive failure (CF) to occur throughout the bonding region, maximizing τ. When the groove pattern is parallel-groove, L ≤ 100 μm, and the number of scans is N = 2–5, CAMG maximizes τ (∼29.34 MPa). To increase efficiency and save energy, the optimal combination of parameters for laser processing CAMG is parallel-groove, L = 100 μm, and N = 2. Compared with laser processing multi-grooves, CAMG improved the processing efficiency by 3.5 % and reduced the laser energy by 35.2 %. The proposed method shows great advantages in improvement of bonding strength.

Microstructural evaluation and mechanical properties of WC-6%Co/AISI 1045 steel joints brazed by copper, brass, and Ag-based filler metals: Selection of the filler material

Due to the higher production cost of the monolithic carbide tools as well as their brittle nature, cemented carbides such as WC-Co are frequently joined to tool steel. To overcome the joining complications that arise due to notable differences in thermal expansions between the components and the poor wettability, various investigators have used copper-based and silver-based filler metals to dissimilarly braze the cemented carbides to steels. However, researchers do not agree about the selection of filler material. This research investigates the use of pure copper, brass, and silver-based filler metals to join the WC-Co cemented carbide to AISI 1045 steel. In this regard, microstructural features and mechanical properties including microhardness and shear strength were studied. The results indicate the formation of Cu(Fe,Co) solid solution and η carbides at the joint interfaces as well as the development of various precipitated phases in the joint area comprising Fe-Zn and Co-Zn intermetallic compounds. The reaction layers at both sides of the joints accompanied by cobalt-depleted zone on the hard metal side were observed. While using the α−β brass interlayer, the increase in hardness of the joint area through the presence of (Cu,Zn) solid solution compared to pure copper, the joint shear strength was enhanced from 161 to 173 MPa. On the other hand, the utilization of silver-based filler alloy with a distribution of hard copper-rich solid solution phase (182 HV) embedded in a silver-rich ductile matrix (88 HV), presenting a dispersion hardening effect, improved the shear strength of the joint to 203 MPa.

Retrofitting RC beam-column joint subassemblies using UHPC jackets reinforced with high-strength steel mesh

Outdated building codes in seismic zones often did not require seismic detailing on beam-column joints, leaving many existing structures vulnerable to earthquakes. To address this issue, three different ultra-high-performance concrete (UHPC) jackets were proposed for retrofitting seismically-deficient exterior beam-column joints, with variables including construction method (cast-in-place or precast) and inclusion of high-strength steel bar meshes. The effectiveness of these jackets was investigated using cyclic loading tests on beam-column joint subassemblages. The results demonstrated that all three UHPC jackets considerably improved the strength, stiffness, and energy dissipation of the beam-column joint subassemblage, as well as both repairable and collapse drifts. However, the cast-in-place UHPC jacket, when not reinforced with steel meshes, failed to effectively improve the ultimate drift capacity of the original beam-column joint subassemblage. Moreover, retrofitting with precast UHPC jackets using chemical anchors failed to generate sufficient composite action. Only the cast-in-place UHPC jacket, when reinforced with high-strength steel meshes, successfully delayed localized joint shear damage and allowed for effective utilization of beam flexural capacity. It improved the joint shear strength by 66%, initial stiffness by approximately 35%, and total energy dissipation by 140%. Finally, strength models were suggested for evaluating the joint shear strength and beam flexural capacity of UHPC-retrofitted beam-column joints.

Interface reactions between copper and 50In-50Pb (wt%) alloy by solid-state aging

This study investigated the interface microstructure that developed between 50In-50Pb (wt%) solder and copper (Cu) base material as a function of solid-state aging. The aging temperatures and times were in the range of 55°C – 170°C and 1 – 350 days, respectively. The analysis examined the intermetallic compound (IMC) layer compositions; the rate kinetics of IMC layer growth; and the role of the IMC layer on solder joint shear strength. The IMC layer transitioned from pseudo-equilibrium compositions towards an equilibrium composition of Cu11In9 (φ phase) with an increased degree of aging, illustrating the non-equilibrium nature of the interface. The rate kinetics for solid-state IMC formation exhibited a time exponent, n, of 0.47±0.09, which indicated a diffusion-controlled reaction. The relatively low, apparent activation energy, ΔH, of 23±4 kJ/mol implied an anomalously-fast diffusion mechanism. The shear stresses were 22±2 MPa and 19±1 MPa for the 0.190 mm and 0.380 mm joint clearances, respectively, representing the as-fabricated condition; the difference reflected the plane strain effect. The crack path remained in the In-Pb solder so that the In-Pb microstructure, not the thickness, composition, or morphology of the IMC layer, controlled shear strength for either joint clearance. The shear strength trends differed between joint clearances due to competing processes in the In-Pb solder. Precipitation and re-solutionization of Cu dissolved in the In-Pb solder controlled the effects of aging on the shear strength of the 0.190 mm joint clearance while traditional recovery and recrystallization mechanisms determined the aging response of the 0.380 mm solder joints.

Achievement of high-strength Al/CFRP hybrid joint via high-speed friction stir lap joining and laser texturing pretreatment parameters variation

This paper presents the achievement of a high-strength Al/CFRP hybrid joint through a high-speed friction stir lap joining process, combined with variations in laser surface texturing pretreatment parameters. The study examined the impact of laser surface texturing parameters by varying the depth, interval distance and width of the laser texture. By adjusting laser texturing parameters, the softened PA66 was fully infused into the textured grooves on the aluminum surface, leading to a significant reduction in interfacial voids and cracks in Al/CFRP. The preliminary tensile shear test showed that the hybrid joint broke at the CFRP base material, indicating that the laser texturing exhibited excellent Al/CFRP interface strengthening ability. Further compression shear tests were applied to reveal the actual interfacial load-carrying performance for comparison. The maximum shear strength of 25.5−1.34+0.7 MPa was achieved at a joining speed of 3000 mm/min. Additionally, a mathematical model was proposed to assess the strengthening impact of laser texturing parameters, considering micro-texture geometry and interfacial defects. The tearing of PA66, detachment of carbon fibers, and the breakage of carbon fibers were the three primary types of fracture modes identified at the Al/CFRP interface. The joining mechanism revealed that both mechanical interlocking and the chemical bonding of Al-O-C contributed to the increase in joint shear strength. This study presents a credible method for producing high-strength Al/CFRP lightweight structures.

Improvement of Solder Joint Shear Strength under Formic Acid Atmosphere at A Low Temperature.

With the continuous reduction of chip size, fluxless soldering has brought attention to high-density, three-dimensional packaging. Although fluxless soldering technology with formic acid (FA) atmosphere has been presented, few studies have examined the effect of the Pt catalytic, preheating time, and soldering pad on FA soldering for the Sn-58Bi solder. The results have shown that the Pt catalytic can promote oxidation-reduction and the formation of a large pore in the Sn-58Bi/Cu solder joint, which causes a decrease in shear strength. ENIG (electroless nickel immersion gold) improves soldering strength. The shear strength of Sn-58Bi/ENIG increases under the Pt catalytic FA atmosphere process due to the isolation of the Au layer on ENIG. The Au layer protects metal from corrosion and provides a good contact surface for the Sn-58Bi solder. The shear strength of the Sn-58Bi/ENIG joints under a Pt catalytic atmosphere improved by 44.7% compared to using a Cu pad. These findings reveal the improvement of the shear strength of solder joints bonded at low temperatures under the FA atmosphere.

New 2D roughness parameters with geometric and physical meanings for rock joints and their correlation with joint roughness coefficient

Determining the joint roughness accurately will better serve the peak shear strength estimation models of rock joints used for stability assessment of rock masses. Considering the defects of the existing quantitative characterization parameters for two-dimensional (2D) joint roughness, especially the lack of explicit geometric and physical meaning, we proposed two new 2D roughness parameters, θ2D and h2D. The former, θ2D, represents the average inclination angle of all potential contact asperities over the entire joint profile, while the latter, h2D, characterizes their average undulation height. Both parameters are closely related to the shear strength of rock joints. Then, the roughness parameters θ2D and h2D of 102 rock joint profiles digitized at 0.5 mm sampling interval were calculated, and a new nonlinear regression equation for the determination of the 2D joint roughness coefficient (JRC) was established by combining the calculated results of the two roughness parameters. It was verified that the proposed equation could give accurate JRC estimation values of the 10 standard profiles of rock joints. Through the comparative analysis of the experimental data collected from earlier studies for the peak shear strength of 73 rock joint samples and corresponding estimated values, the equation was further verified to be applicable and accurate for estimating the JRC values of rock joints. Furthermore, we discussed the effects of shear direction and sampling interval on roughness and further provided another equation that could be applied to estimate the JRC values of joint profiles at the sampling interval of 1.0 mm.

Study of the effect of bio-inspired surface texture on the shear strength of bonded 3D-printed materials: Comparison between stainless steel and polycarbonate joints

Additive Manufacturing (AM) is one of the important technological pillars of Industry 4.0. Thanks to its tool-free manufacturing and extreme flexibility, AM has the potential to respond to individual customer preferences with a customized final product. Nevertheless, the size of 3D printed products is limited by the size of the build chamber of commercially available printers. In addition, deformations, stability, tolerances, and especially cost are highly dependent on the maximum size of the parts. Therefore, a larger final product can only be realized as an assembly group. Therefore, adhesive bonding appears to be an attractive solution for assembling parts made by AM. In this paper, a comparison of the influence of surface texture on the shear strength of 3D-printed metallic and polymeric adhesive joints was performed. A fish scale (FS) bio-inspired surface texture was chosen to examine how surface patterning influences the strength of joints. Fused deposition modeling (FDM) and selective laser melting (SLM) techniques were used to produce polycarbonate (PC) and stainless steel (17-4 PH) specimens, respectively. The effect of bio-surface and material type on the shear strength of adhesive joints was assessed using the ASTM D4501 standardized block shear testing method. The morphological analysis revealed that FDM exhibits reduced resolution and accuracy, making it less suitable for the additive manufacturing of complex surface features in 3D-printed parts when compared to SLM technology. In addition, bio-surface texturing significantly improved the wettability of stainless steel, requiring the synergy of higher surface free energy and increased surface roughness (FS bio-surface) for super-hydrophilicity, while a combination with lower surface free energy (PC material) and the same surface roughness resulted in hydrophobic behavior. On the other hand, the bio-surface texture greatly enhanced the shear strength (+31%) of stainless steel specimens, compared to PC specimens, due to the increase of physical adsorption forces and the enhancement of the mechanical interlocking effect. The analysis of variance (ANOVA) results highlight the predominant influence of material type on surface wettability (84%), while surface texture has a more pronounced impact on the shear strength of bonded joints (71%).

Pre-plating Cu on the WC–Co surface to inhibit Co-depletion zone and enhance the shear strength of WC–Co/40Cr joints

The Co-depletion zone in WC–Co brazed joints is the main zone of joint failure, so it is crucial to explore novel processes to inhibit the Co-depletion zone and enhance the joint shear strength. In this study, a composite process of pre-plating Cu on the WC–Co surface + brazing was designed. Co-depletion zone reduces from 6 μm to 1 μm due to the Cu plating. Meanwhile, the formation of a plating fusion zone in the filler layer transforms TiCo with a thickness of 2.5 μm into a small number of TiCo particles. Moreover, the high concentration of Cu atoms in the vicinity of the WC particles at the interface changes the Co-segregation layer in the WC into a Cu-rich layer. The concentration of Cu in the filler layer leading to precipitation of TiCu and Ti2Cu particles. Ti2Cu particles encapsulated by ductile Ag–Cu–In ternary eutectic contribute to inhibit the cracks propagation. The shear strength of the joints was enhanced by 51.3 % to 295 MPa. The composite process of pre-plating on the base material surface + brazing has positive significance in inhibiting the excessive diffusion of elements from the base materials to the filler layer.

Strong composite SnAgCu solder joints with internal aligned carbon fibers by magnetic field

Lightweight carbon fibers with high mechanical performance are referred to as an ideal reinforcement for an extensive variety of composite materials. However, the addition of carbon fibers into electronic interconnection solders is extremely limited so that the expected reinforcement in the mechanical properties of the composite solder joints has not been completely realized. Here, we used magnetic fields to align Ni-coated carbon fibers in the Sn-3.0Ag-0.5Cu solder vertically with the Cu substrate and prepared the oriented composite solder joints. We achieved a further improvement in the shear performance of composite solder joints (∼58 MPa) with a small addition of Ni-coated carbon fibers (0.5 wt%), which is 25% higher than that of pristine joints. It is found that these vertically oriented carbon fibers changed the propagation path of shear cracks and thus increased the shear resistance. Ni-coated carbon fibers also promoted nucleation of interfacial Cu6Sn5 in the solder joints during reflow, but prevented the formation of brittle Cu3Sn phase during isothermal aging, thus ensuring the high shear strength of composite solder joints after isothermal aging. This success provides a new pathway to fabricate a strong composite solder joint with a limited addition of reinforcements by aligning their orientation.