Lap Shear Strength Research Articles

Experimental evaluation of atmospheric plasma treatment effects on different textures of CFRP composite for aircraft applications

This article examines the impact of Atmospheric Plasma Treatment (APL) on the chemical composition and fracture properties of various textured surfaces (tool and bag side) of carbon fiber/epoxy (CFRP) composites utilized in aircraft applications. For this purpose, parameters of atmospheric plasma (APL) surface treatment were evaluated in comparison to chemical cleaning and peel-ply applications, taking into account its effects on surface properties and adhesive bond strength. A comprehensive variety of surface characterization techniques were utilized to analyze surface modifications, including water and diiodomethane contact angle measurements for assessing surface hydrophilicity, Fourier Transform Infrared Spectroscopy with Attenuated Total Reflection (FTIR-ATR) and X-ray Photoelectron Spectroscopy (XPS) for analyzing chemical composition and functional groups, and Profilometry, Atomic Force Microscopy (AFM), and Scanning Electron Microscopy (SEM) for evaluating surface topography and morphology. Experimental results indicated that the reduction in the contact angle following plasma treatment correlated with the elevated oxygen concentration and the presence of polar functional groups (e.g. -OH, -NH2, -NH3, C=O, O-C=O) on the composite surface. Plasma treatment, especially at low nozzle speeds, increased surface roughness on the bag side surfaces. This prevented adhesive penetration and led to gas entrapment, resulting in adhesive failure mode and reduced single lap shear strength for the bag side. In contrast, on the tool side surfaces, the plasma treatment led to a remarkable 19.7% enhancement in shear strength, highlighting its effectiveness.

Evaluating the Influence of Tool Material on the Performance of Refill Friction Stir Spot Welds in AA2029

Joining high strength 2xxx series aluminum is known to be complex and difficult; these alloys are traditionally considered non-weldable for fusion welding. This paper describes details on welding AA2029-T8 for skin-stiffened structures using refill friction stir spot welding (RFSSW). RFSSW is a solid-state process invented in the early 2000s that produces spot welds that are strong, lightweight, flush, and hermetic. Cycle times between 1 and 3 s are discussed, and process forces within a range of 8 to 14 kN are demonstrated. Furthermore, lap-shear quasi-static tensile strengths are shown to be between 10 kN and 12 kN in 9 mm diameter spots. A comparison of the performance of RFSSW welds made with various tool materials—which include H13 tool steel, tungsten carbide, and MP159—is detailed. Comparisons of parameters, weld consolidation, and heat-affected zones are presented with discussion related to heat generation specific to each tool material.

Influence of air DBD plasma treatment on the shear and flexural strength of adhesively bonded glass fiber reinforced epoxy composite joints

In this study, air dielectric barrier discharge (DBD) plasma treatment was applied at various voltages and treatment durations to improve the bonding strength of glass fiber reinforced epoxy composites (GF/EP). In addition, single lap shear and three-point bending strengths of adhesively bonded joints were compared between untreated and surface-treated (sanding, peel ply, and plasma) samples. Surface properties of GF/EP composites were examined using contact angle, surface free energy, X-ray photoelectron spectroscopy (XPS), Scanning electron microscopy (SEM), and Atomic Force Microscopy (AFM). Then, mechanical tests (single lap shear and three point bending) were performed and the damage modes were determined. Surface analyses revealed that wettability and polar functional groups increased on the GF/EP surface after plasma treatment. From the mechanical test results, it was observed that the plasma treatment applied to GF/EP composites increased both single lap shear and flexural strength compared to untreated, sanding and peel ply surface treatments. After both single lap shear and 3-point bending tests, adhesive, and light fiber tear failure modes were observed.

Significantly enhanced joint strength and fatigue life of aerospace composite joints by using novel PEEK/PPS woven meshes as joining agent

The development of advanced joining methods for carbon fibre/epoxy composites is critical for aerospace applications. Herein, advanced PEEK/PPS meshes were used to join carbon fibre/epoxy composites upon a novel co-curing process. The meshes were surface-activated upon an atmospheric plasma technique, which largely promoted the chemical interactions between the meshes and the composite epoxy matrix. The quasi-static joint strengths at both of 22 °C and 130 °C and fatigue loading resistance of the composite joints were evaluated using a single-lap joint test and the corresponding failure mechanisms were investigated. Encouragingly, the lap-shear strengths and fatigue resistance of the PEEK/PPS mesh-joined composites were larger than that of their counterparts bonded by an aerospace adhesive. Subsequent analysis on the failure surfaces proved PEEK/PPS fibre damage and epoxy crack were the main failure mechanisms of the PEEK/PPS co-cured joints. This work proposed a novel method for the production of robust aerospace joints by co-cure joining the composites using advanced PEEK/PPS meshes.

Study on the preparation of an epoxy-based electromagnetic wave-absorbing adhesive film and its hygrothermal aging

With the wide application of structural adhesives in the aerospace field, the structural adhesive films with only bonding property have not met the current needs. The structural-functional integrated adhesive films have become the current study hotspot. In this paper, an epoxy-based electromagnetic wave-absorbing adhesive film was prepared by adding the magnetite/SWCNTs as the absorbing agent to the epoxy adhesive. And then, it was subjected to hygrothermal aging for 1500h at 70°C and 90% RH. The results show that the absorbing filler was uniformly dispersed in the epoxy resin matrix. The reflection loss (RL) peak of the magnetite/SWCNTs/epoxy adhesive film reached −27.5 dB at the frequency of 8.75 GHz when the absorbing agent content was 20 wt%. The effective bandwidth was 3 GHz with 25 wt% absorbent content. Moreover, after 1000h of hygrothermal aging, the lap shear strength of the magnetite/SWCNTs/epoxy adhesive film decreased by 19.6%, indicating that it can perform excellent service under hygrothermal conditions.

Effect of the Energy Director Material on the Structure and Properties of Ultrasonic Welded Lap Joints of PEI Plates with CF Fabric/PEI Prepreg

To estimate the possibility of using both low-melting TecaPEI and neat PEI films as energy directors (EDs) for ultrasonic welding (USW) of carbon fiber (CF) fabric–polyetherimide (PEI) laminates, some patterns of structure formation and mechanical properties of their lap joints were investigated by varying the process parameters. The experiment was planned by the Taguchi method with the L9 orthogonal matrix. Based on the obtained results, USW parameters were optimized accounting for maintaining the structural integrity of the joined components and improving their functional characteristics. The use of the low-melting EDTecaPEI film enabled US-welding the laminates with minimal damage to the fusion zone, and the achieved lap shear strength (LSS) values of ~7.6 MPa were low. The use of EDSolverPEI excluded thermal degradation of the components as well as damage to the fusion zone, and improved LSS values to 21 MPa. With the use of digital image correlation (DIC) and computed tomography (CT) techniques, the structural factors affecting the deformation behavior of the USW lap joints were justified. A scheme was proposed that established the relationship between structural factors and the deformation response of the USW lap joints under static tension. The TecaPEI film can be used in USW procedures when very high interlayer adhesion properties are not on demand.

Sandwich-structured nano-adhesive based on the synergistic action of two nanoparticles (SiC and MWCNTs)

This study encompasses the development of sandwich-structured adhesive reporting the synergism in the functioning of two kinds of nanoparticles (NPs)-SiC (Silicon carbide) and MWCNTs (multiwalled carbon nanotubes). Two adhesives using MWCNTs and NPs of SiC in selected amounts were developed using Polyaryletherketone (PAEK) thermoplastic polymer as a base matrix. Fabricated joints using these adhesives were characterized for degglomeration and dispersion of NPs, lap shear strength (LSS), and failure modes. Based on the data on the LSS, the advantages and disadvantages of using individual NPs were analyzed, and the third adhesive was designed in a sandwich manner, where positive points of both the NPs were expected to work synergistically. The sandwich adhesive showed higher LSS than the individual ones, i.e., an 8.6% and 26% improvement to SiC-based and MWCNT-based adhesives, respectively. It was concluded that the strengthening mechanism of MWCNTs of bulk polymer in the central portion was beneficial. The two outer layers of SiC NPs in PAEK interacting with the two steel surfaces of coupons proved helpful in increasing friction and, hence, synergistically increasing the LSS of sandwich adhesive.

Crosslinkable latex-based acrylic adhesives containing functionalized cellulose nanocrystals (fCNCs)

In this study, crosslinkable acrylic adhesives with functionalized cellulose nanocrystal (fCNCs) were prepared via in situ emulsion polymerization at 80 °C for 3h. The neat acrylic pressure sensitive adhesives (PSAs) without any nanoparticles were prepared using butyl acrylate (BA), 65 wt%, and methyl methacrylate (MMA), 35 wt%, and various amounts of 2-hydroxyethyl methacrylate (HEMA), 1, 3, 5, 7 wt% based on total BA and MMA monomers. For preparing fCNCs reinforced adhesives, the cellulose nanocrystals (CNCs) were functionalized using various concentrations of 3-methacryloxypropyl trimethoxy silane (MPS), 5, 20, 40 mM. The cellulose nanocrystals (CNCs), functionalized cellulose nanocrystals (fCNCs), and the prepared adhesives were characterized by Fourier transform infrared (FTIR) spectroscopy, field emission scanning electron microscopy (FESEM), X-ray diffraction (XRD), thermal gravimetric analysis (TGA), and differential scanning calorimetry (DSC). The Adhesion performance of the adhesives was evaluated by lap shear and 180° peel tests. The results showed that increasing the HEMA content as crosslinking agent in the adhesive structure, enhanced its gel content, glass transition temperature (Tg), thermal stability, and adhesive performance, i.e. lap shear and peel strength. Finally, the adhesive containing 5 wt% HEMA was selected as the appropriate sample. Thereafter, the adhesives containing 5 wt% HEMA were synthesized in the presence of various amounts of fCNCs, i.e. 0.5, 1, 1.5 wt%. The Adhesion performance of the neat and reinforced adhesives indicated that increasing the fCNCs to the adhesive enhanced thermal stability, gel content, lap shear and peel strength. Additionally, the fCNCs prepared using higher concentration of MPS (40 mM) was more effective on the adhesion performance than the fCNCs prepared with the lower MPS contents, 5, 20 mM. The results showed that the adhesives prepared using 1 wt% and 1.5 wt% of fCNC40 (containing 40 mM MPS) exhibited better adhesion performance.

Ultrasonic welding of CF/PA6 composite to 6061Al alloy utilizing an interfacial coating as energy director

This study investigates ultrasonic plastic welding to join the carbon fiber-reinforced thermoplastics and 6061Al alloy in a lap-type joint configuration. An interfacial polymer coating through a fluidized bed on aluminum alloy was considered an energy director, as it was essential for concentrating heat at the interface during welding. The significant ultrasonic process setting (weld pressure: 0.5 MPa, weld time: 600 ms, hold time: 1000 ms) was statistically realized for a maximum lap shear strength of the joint that showed the interlaminar shear (first-layer ply) failure of the composite, while the welding interface morphology revealed interdiffusion of thermoplastics with the load-bearing carbon fibers attached to the composite-coating resin mixtures, whereas the coating interface offered a strong adhesion of polymer on the aluminum surface asperities through mechanical interlocking. An efficient multi-material joint was obtained within 1.6 s in comparison to the adhesive bonding technology that required at least 20 min. Additionally, the interfacial coating serves as an insulator, avoiding galvanic corrosion in joints as well as fretting damage. The encouraging findings of this research provide deeper insight into joining thermoplastic composites to metals by ultrasonic plastic welding without the use of a separate energy director, which simplifies the process of industrialization.

Lignin reinforced tough, adhesive and recoverable protein organohydrogels for wearable strain sensing under sub-zero temperatures

Protein-based hydrogels with promising biocompatibility and biodegradability have attracted considerable interest in areas of epidermal sensing, whereas, which are still difficult to synchronously possess high mechanical strength, self-adhesion, and recoverability. Hence, the bio-polymer lignosulfonate-reinforced gluten organohydrogels (GOHLx) are fabricated through green and simple food-making processes and the following solvent exchange with glycerol/water binary solution. Ascribing to the uniform distribution of lignosulfonate in gluten networks, as well as the noncovalent interactions (e.g., H-bond) between them, the resultant GOHLx exhibit favorable conductivity (~14.3 × 10−4 S m−1), toughness (~711.0 kJ m−3), self-adhesion (a maximal lap-shear strength of ~33.5 kPa), high sensitivity (GF up to ~3.04) and durability (~3000 cycles) toward shape deformation, which are suitable for the detection of both drastic (e.g., elbow and wrist bending) and subtle (e.g., swallowing and speaking) human movements even under −20 °C. Furthermore, the GOHLx is also biocompatible, degradable, and recoverable (by a simple kneading process). Thus, this work may pave a simple, green and cheap way to prepare all-biomass-based, tough, sticky, and recoverable protein-based organohydrogels for epidermal strain sensing even in harsh environments.

Evaluation of sustainable composites of sugarcane bagasse and combined algae-soy protein binders

The development of sustainably-sourced adhesives is essential to displace conventional particleboard adhesives made from formaldehyde and other petroleum derivatives. This work evaluates the mechanical properties of particleboards prepared from sugarcane bagasse, spirulina algae powder, soy flour, and sodium hydroxide at various algae to soy ratios and denaturation times. The rheology of the adhesive was characterized using the Hershel-Bulkley method to determine the yield stress (max. 288 Pa) and flow behavior index (0.21–0.54). The lap shear strength (max. 3.02 N/mm2) was also determined. For the particleboard, the secant modulus of elasticity (max. 1.12 GPa), tangent modulus of elasticity (max. 1.30 GPa), modulus of rupture (max. 11.62 N/mm2), and internal bond strength (max. 0.09 N/mm2) were determined. These particleboards met the minimum requirement set by ANSI/A208.1–1999 for general-use particleboards for the modulus of elasticity and modulus of rupture, but they did not meet the standard for internal bond strength.

The Role of Surface Treatment and Coupling Agents for Adhesion between Stainless Steel (SUS) and Polyamide (PA) of Heterojunction Bilayer Composites.

The growing demand for lightweight and durable materials in industries, such as the automotive, aerospace, and electronics industries, has spurred the development of heterojunction bilayer composites, combining the structural integrity of metals with the versatility of polymers. This study addresses the critical interface between stainless steel (SUS) and polyamide 66 (PA66), focusing on the pivotal role of surface treatments and various silane coupling agents in enhancing the adhesion strength of heterojunction SUS/PA66 bilayer composites. Through systematic surface modifications-highlighted by scanning electron microscopy, atomic force microscopy, and contact angle analyses-the study assessed the impact of increasing the surface area, roughness, and energy of SUS. X-ray photoelectron spectroscopy evaluations confirmed the strategic selection of specific silane coupling agents. Although some coupling agents barely influenced the mechanics, notably, aminopropyl triethoxysilane (A1S) and 3-glycidyl oxypropyl trimethoxysilane (ES) significantly enhanced the mechanical properties of the heterojunction bilayer composites, evidenced by the improved lap shear strength, elongation at break, and toughness. These advancements were attributed to the interfacial interactions at the metal-polymer interface. This research underscored the significance of targeted surface treatment and the judicious selection of coupling agents in optimizing the interfacial adhesion and overall performance of metal-polymer composites, offering valuable insights for the fabrication of materials where reduced weight and enhanced durability are paramount.

Reprocessable and self-healable boronic-ester based poly(styrene-b-isoprene-b-styrene) vitrimeric elastomer with improved thermo-mechanical property and adhesive performance

It is fascinating to develop vitrimeric elastomers with excellent processability and improved physical properties through incorporating reversible covalent bonds into traditional thermoplastic elastomers. In this work, a poly(styrene-b-isoprene-b-styrene) (SIS) thermoplastic elastomer was selected as the base elastomer and converted into vitrimer through peroxide-induced crosslinking reaction with di-vinyl-terminated boronic ester crosslinker. Kissinger model predicts that the activation energy of vitrimer crosslinking process is slightly higher than that of chemical crosslinking process. The peroxide content was adjusted to tune the composition of permanent chemical crosslinks and dynamic chemical crosslinks. In this way, SIS vitrimer elastomer with tailored multiple network structure was successfully prepared. The stress relaxation behavior of all SIS-BE samples shows Arrhenius-type temperature-dependency and the bond-exchange activation energy (Ea) of SIS-D0.5-B5 sample was estimated as 44.14 kJ/mol. SIS vitrimer elastomer shows improved creep-resistance, comparative mechanical strength and elastic recovery in relative to crosslinked SIS elastomer while maintaining good reprocessbility and self-healing efficiency. Additionally, SIS vitrimeric elastomer shows an increased lap-shear strength from 0.53 MPa to 1.02 MPa with the increase of DCP content. Therefore, we have demonstrated the potential for industrial-scale production of SIS vitrimer elastomer and its applications as reprocessable and healable adhesives.

Optimization and GRA prediction of Al–Cu pulsed laser welding process based on RSM

In this paper, the process parameters of pulsed laser welding of Al–Cu are studied using response surface methodology (RSM) and grey relation analysis (GRA) to propose optimal directions for lap-shear strength of the joints. A single-factor experiment was conducted to find the suitable process parameter windows. The RSM models were established and analyzed with laser power, welding speed, pulse width, and frequency as inputs and joint lap shear, interfacial weld width, and weld-penetration-depth as outputs. With the use of GRA of interfacial weld width and weld penetration depth with the lap-shear force of joints, the improved direction for the lap-shear force of joints can be proposed.

Improving the quality of resistance welded thermoplastic composite joints by applying ultrasonic

Resistance welding, a favored method for joining thermoplastic composites, often faces the challenge of nonuniform bonding which leads to weak bonding at the overlap edge and compromises joint integrity. This study proposes a novel modification to traditional resistance welding by incorporating ultrasonic during the final stage of the process. We employed various durations of resistance welding and ultrasonic to join the GF/PPS composites, which yielded significant improvements in bonding strength and welding efficiency. Applying ultrasonic introduced a self-adaptive temperature compensation mechanism, enhancing the temperature at the overlap edge while diminishing the temperature difference between the center and edge of the overlap. This method also improved fusion bonding by encouraging resin flow along the unfused interface at the overlap edge, thereby expanding the bonding area. Notably, the introduction of ultrasonic revealed a new bonding mechanism involving the interaction between molten PPS and unmelted PPS, which was thoroughly examined. The results revealed a 19% increase in lap shear strength and a 40% reduction in welding time for joints with ultrasonic compared to those without ultrasonic.

Effect of atmospheric plasma treatment and wet blast on adhesion characteristics of carbon fiber reinforced LM-PAEK thermoplastic composites

Surface characteristics of polymeric materials are quite challenging for adhesion especially thermoplastics, requiring specific surface preparation operations before reaching successful bonding. These processes are principally aimed to increase the low surface energy of the material, bonding agent contact area and wetting characteristics to provide proper and strong adhesion. In this study, two different surface treatments with different processing parameters were applied to CF/LM-PAEK thermoplastic composites in order to examine the changes on surface characteristics and adhesion strengths. Apart from desired surface treatments for thermoplastics indicated in previous studies and backgrounds, wet blasting method is used to prepare surfaces before bonding. Separately prepared surfaces, applying wet blasting and atmospheric plasma treatment, were adhered using epoxy-based film adhesive to be subjected to single lap shear testing to examine adhesion strength under tensile loading. According to the results of experimental study, it was observed that both surface treatments increased the adhesion strength of the bonded pre-consolidated CF/LM-PAEK thermoplastic composites compared to specimens having untreated surfaces.Atmospheric plasma treatment increased the surface energy by 18.24% and showed higher strength up to 14.93% compared to the untreated specimens. On the other hand, surprisingly, wet blasted specimens with lower surface energies showed high strength up to 6.48% compared to the untreated specimens. In addition to surface energies and lap shear strengths, roughness measurements and SEM surface evaluations were also issued to enlighten obtained test results accordingly.

A comprehensive investigation on tensile behavior of surface‐modified Kevlar hybrid nanocomposites for similar and dissimilar joints

AbstractThe main objective of this study is to enhance the interfacial adhesion between Kevlar fiber‐reinforced epoxy composite for a single lap joint. This has been achieved by performing various chemical treatments on Kevlar fiber. Moreover, the nanofiller‐added epoxy matrices were also used for investigating its potentiality in a single lap joint. A thorough comparison has been made among various chemical treatments based composite and modified epoxy matrix composite. The tensile strength of similar and dissimilar single lap joints was investigated through experiments and was analyzed by SEM, XRD, and Weibull model. It was perceived that the tensile shear strength and Weibull modulus of the treated similar Kevlar lap joint were 21.45% and 40.18% higher than the similar nanocomposite joint; also, it has been found that an increment of about 79.8% and 76.64% with that of untreated similar Kevlar joint. Furthermore, the failure progression of optimized joints was evaluated by acoustic emission (AE) monitoring.Highlights Interfacial adhesion study of Kevlar fiber with matrix in single lap joint. Kevlar surface modification and epoxy modified by nanocomposites were used. The lap shear strength of similar and dissimilar single lap joint composites. SEM, XRD, and Weibull analysis and AE monitoring were used for this research. Chemical treatments on Kevlar fiber have enhanced the interfacial adhesion.

Static and Dynamic Mechanical Behavior of Carbon Fiber Reinforced Plastic (CFRP) Single-Lap Shear Joints Joule-Bonded with Conductive Epoxy Nanocomposites

The potential of electrically conductive graphene nanoplatelets (GNPs)/epoxy, multi-walled carbon nanotubes (MWNCTs)/epoxy and hybrid GNPs-MWCNTs/epoxy nanocomposites as adhesives for out-of-autoclave (OoA) and in-the-field CFRP repair via Joule heat curing was investigated. Scanning electron microscopy revealed a good dispersion of the nanoparticles in the matrix in all the nanocomposite adhesives above their percolation thresholds, which led to a homogeneous distribution of the heat generated during Joule CFRP repair. The joints bonded with neat epoxy and the nanocomposites showed similar lap shear strengths, with the addition of nanoparticles enhancing the fatigue performance of the adhesively bonded joints relative to when neat epoxy was used as an adhesive and oven-cured. The interfacial and cohesive failure mechanisms were found to coexist in all the cases, with an increasing dominance of the cohesive when nanofillers were embedded into the adhesive. No effect of the specific type of nanofiller incorporated into the epoxy as the conductive component was observed on the mechanical performance of the bonded joints, with the adhesives containing MWCNTs showing similar results to those filled with GNPs at considerably lower loadings due to their lower percolation thresholds. The independence of the properties regardless of the curing method highlights the promise of these Joule-cured adhesives for industrial applications.

An experimental investigation on feasibility of submerged ultrasonic spot welding of thermoplastics

Although conventional methods such as mechanical fastening, adhesive bonding and hot air welding have proven effective in dry conditions, they exhibit diminished efficacy in submerged environments. Hence, a thermoplastic welding technique with minimal dependence on surrounding media is essential. Ultrasonic spot welding (USW) represents a promising approach to thermoplastic joining, offering high efficiency and low operating costs. In this study, we investigate the efficacy of water-submerged ultrasonic spot welding (S-USW) for joining amorphous polyvinyl chloride (PVC) to PVC and semi-crystalline polypropylene (PP) to PP under submerged conditions. Our experimental results show that S-USW leads to a remarkable 39% and 21% increase in lap-shear strength for PVC/PVC and PP/PP welds, respectively, as compared to traditional USW techniques. We corroborate these findings with additional metrics such as Shore-D hardness tests, optical microscopy and scanning electron microscopy imagery, which collectively confirm the improved efficacy of S-USW over USW for joining PVC and PP.

Preparation of tannic acid-reinforced cellulose nanofiber composites for all-water-based high-performance wood adhesives

Traditional adhesives easily release toxic gases during the preparation process or apply to wood composite products, which have adverse effects on the human body and the environment. Herein, an all-water-based high-performance wood adhesive is prepared using TEMPO-oxidized cellulose nanofiber (TOCNF), acrylamide (AM), and tannic acid (TA) through free radical polymerization. Different characteristics of the prepared composites, including morphology, injectability, and adhesion properties, have been investigated. Results showed that the TA/TOCNF/PAM composite has excellent injectability. The addition of TA can enhance the lap shear strength of the TA/TOCNF/PAM composites and with the increment of TA content, the lap shear strength gradually decreases. The formation of effective hydrogen bonds and Van der Waals interaction among the rich functional groups in the composite, lead to strong lap shear strength on different substrates. The composite with 5.0 g of AM, 5.0 g of the TOCNF suspension and 0.1 g TA possesses a high lap shear strength of 10.5 MPa on wood and 1.5 MPa on aluminium. Based on strong adhesion properties and excellent injectability, the TA/TOCNF/PAM composites have great potential in the furniture construction and building industries.