Single Lap Shear Tests Research Articles

Investigations of strength and quality of clinched joints using digital image correlation

ABSTRACT This study examines the impact of processing conditions on joint strength and the effectiveness of digital image correlation (DIC) in detecting failure points in clinched joints. Mechanical tests, including single-lap shear and pull-out tests, were conducted using DIC to evaluate joint quality in various clinched configurations. The results showed frequent failures at the neck rejoin in clinched joints between mild steel and aluminum sheets, particularly when thinner sheets were positioned on the punch side and softer materials on the die side. DIC effectively identified defects and failure locations, offering insights into material combinations, sheet positioning, and failure modes. Although DIC was useful in detecting defects in both elastic and destructive regions, its ability to distinguish specific defect types from strain contour maps was limited. The study highlights the need for further research to extend DIC’s application to other mechanical joining systems and advocates for its proactive use in refining designs and manufacturing processes.

Bond behaviour between near surface mounted CFRP and concrete members using magnetized bond agent under different temperature degrees

ABSTRACT In this investigation, the bond performance between CFRP and concrete in Near Surface Mounted (NSM) strengthening system using cementitious-based adhesive (CBA) was evaluated at different exposure temperatures. Two types of CBA were used (CBA-A and CBA-B) with and without magnetic water (MCBA-A and MCBA-B). Magnetic device with magnetic strength of 9000 Gauss was used to magnetise the water for 15 mins with a flow rate of 0.1 m3/hr. The bond efficiency was evaluated by performing single-lap shear tests for CFRP laminate embedded in concrete prisms as a near surface-mounted strengthening system. The bond between CFRP and concrete was tested under ambient and high temperatures. The heating regime involves the exposure of NSM CFRP/concrete samples to constant temperature (200°C) for 2 hrs, then the load was applied until failure. In comparison with control samples, an improvement of 40% in the load failure was achieved for specimens strengthened with CFRP using magnetised water in CBA. Within the MCBA samples, higher failure load was conducted for MCBA-B samples when compared with samples of MCBA-A since the latter contain primer in its compositions in which its properties deteriorate by high temperature. All tested samples showed similar failure pattern, which is slippage of CFRP.

Single-Lap Shear Testing of a Boron-Free Cu–Mn–Ni Filler Metal for Brazing IN625

Single-Lap Shear Testing of a Boron-Free Cu–Mn–Ni Filler Metal for Brazing IN625

Synthesis and Characterization of Rebondable Polyurethane Adhesives Relying on Thermo-Activated Transcarbamoylation.

Dynamic polymer networks combine the noteworthy (thermo)mechanical features of thermosets with the processability of thermoplastics. They rely on externally triggered bond exchange reactions, which induce topological rearrangements and, at a sufficiently high rate, a macroscopic reflow of the polymer network. Due to this controlled change in viscosity, dynamic polymers are repairable, malleable, and reprocessable. Herein, several dynamic polyurethane networks were synthetized as model compounds, which were able to undergo thermo-activated transcarbamoylation for the use in rebondable adhesives. Ethylenediamine-N,N,N',N'-tetra-2-propanol (EDTP) was applied as a transcarbamoylation catalyst, which participates in the curing reaction across its four -OH groups and thus, is covalently attached within the polyurethane network. Both bond exchange rate and (thermo)mechanical properties of the dynamic networks were readily adjusted by the crosslink density and availability of -OH groups. In a last step, the most promising model compound was optimized to prepare an adhesive formulation more suitable for a real case application. Single-lap shear tests were carried out to evaluate the bond strength of this final formulation in adhesively bonded carbon fiber reinforced polymers (CFRP). Exploiting the dynamic nature of the adhesive layer, the debonded CFRP test specimens were rebonded at elevated temperature. The results clearly show that thermally triggered rebonding was feasible by recovering up to 79% of the original bond strength.

Finite element modeling for cohesive/adhesive failure of adhesive structures with a thermosetting resin

In this study, we established a novel method based on the finite element method (FEM) for predicting the strength of adhesive structures. Viscoplasticity, void growth, and cohesive zone model were introduced into the FEM to create a nonlinear damage growth (NDG) model. This model was used to comprehensively analyze the process zones within the adhesive layer. Furthermore, the embedded process zone approach was used to develop an interface constitutive law that averages the mechanical response of the adhesive layer. This modified Ma–Kishimoto (MMK) model can accurately represent the adhesive layer as an interface element and is computationally efficient. Furthermore, the study obtained the necessary interface properties for the MMK model from the NDG model, creating a numerical material test that can approximate the effect of the process zone. To validate the proposed method, single-lap shear tests were performed, and the accuracy of the predicted strength and deformation field was evaluated. The damage evolution in the NDG model and the MMK model were compared, and the scope of application of the MMK model was discussed. The results of this study can be used as a reference for the failure mechanism of thermosetting adhesives and establishment of design indices for adhesive structural strength.

Comprehensive FRP-concrete bond behavior: Impact of test methods and the innovative UBoT

The lack of a standardized bond test method for fiber-reinforced polymer (FRP)-concrete interfaces leads to variations in forms of the popular single-lap shear, double-lap shear, beam, mixed-mode, and pull-off tests. Recognizing the limitations of each bond test technique and the importance of analyzing all results as complementary, a detailed evaluation of these variations is essential for accurate bond behavior assessment prior to design and field deployment, to avoid subjective decisions and predictions. This study pioneers the evaluation of FRP-concrete bond test methods, offering the industry a consistent dataset for informed decision-making. Single- and double-lap shear tests yield trilinear bond-slip responses; however, the single-lap test’s lack of symmetry reduces bond strength by 15% compared to the double-lap test. The beam test, unsuitable for bond-slip modeling, shows comparable average bond strength to the single- and double-lap tests. The mixed-mode test better simulates field applications, while the pull-off test provides the most consistent results. Given that each test method reflects only one field scenario, the Universal Bond Tester (UBoT) was developed. This device can convert to all FRP-concrete bond test types. It also addresses the modified double-lap shear test’s limitations (e.g., inapplicability to pultruded laminate and FRP rupture in wet layup systems) and present a modified ASTM D7958 beam and mixed-mode tests cost-effectively. The UBoT captures full bond behavior and variabilities, overcoming the limitations of existing methods which fail to capture all failure modes in bond-critical applications. It reduces specimen sizes, weight, and data acquisition needs by half for most tests. This study allows test laboratories to use any preferred testing method with the UBoT. Link to video demonstrations for all tested specimens are provided in the supplementary material.

Imparting semi-permanent demoldability to stainless steel mold using surface-initiated solution polymerization of stearyl methacrylate

The growing market demand for compact and precisely-designed polymeric products has raised challenges during the demolding stage of manufacturing. An increased contact area between the product and the mold increases adhesion, which reduces dimensional stability and aesthetics. Conventional solutions like surface roughness improvement or release agent coatings suffer from reduced productivity and impurity-related issues affecting mechanical properties. To address these challenges, we imparted the semi-permanent demoldability to a stainless steel (SUS) mold by polymerizing stearyl methacrylate monomer on its surface using a surface-initiated solution polymerization technique. The polymerization state was confirmed through Fourier transform infrared spectroscopy and field emission scanning electron microscopy. The demoldablity was investigated using the appropriately-designed lap shear tests to simulate the demolding stage of epoxy resin-filled SUS mold to ensure sufficient performance compared with the neat and commercial release agent (RA) treated molds, and durability of the demoldability was confirmed via repetitive single-lap shear tests simulating the molding and demolding processes. The surfaced polymerized mold exhibited excellent demoldability with 96.5 % improvement over the neat one, and showed excellent durability over 5 repeated molding cycles, while the commercial RA showed significant degradation of demoldability. Furthermore, the mechanism of demoldability enhancement using the proposed surface polymerization was investigated by characterization of the surface dewetting pattern and contact angle measurements of the epoxy resin on the modified mold surface.

Robust ultrasonically welded CF/PEI-CF/epoxy composite joints upon tailoring the thermoplastic resin thickness at the welding interface

The objective of this study was to develop robust carbon fiber/epoxy (CF/epoxy)-carbon fiber/polyetherimide (CF/PEI) hybrid joint upon an ultrasonic welding process. The co-curing of a PEI coupling layer (CL) on the surface of the CF/epoxy composite makes it “meltable and weldable”. The CF/epoxy was then ultrasonically welded with the CF/PEI using different combinations of energy director (ED) and CL thicknesses. The results showed that high-quality welding line could be obtained by carrying out coupling-optimization to the thicknesses of the EDs and CLs using an optimal welding displacement. For example, a largest lap-shear strength (LSS) of 35.3 MPa was achieved when both of the ED and CL possessed an optimal thickness of 175 μm. In this case, a cohesive failure within either the CF/PEI or the CF/epoxy substrate took place during the single-lap shear test of the hybrid joints. Predictably, this study provides a promising strategy for the production of high-performance hybrid composite joints upon tailoring the thicknesses of the EDs and the CLs for the ultrasonic welding process.

Theoretical study on the bond performance of CFRP-to-steel single-lap shear tests with multiple debonding defects

The amount of research on the external bonding of Carbon Fiber Reinforced Polymers (CFRP) to degraded structures has increased recently. The adhesive is the weakest element of the joint and the bonding of the adherends is critical for the efficiency of the joint. Therefore, the influence of multiple debonding defects on CFRP-to-steel joints has still not been correctly quantified nor fully understood. For this reason, the current work proposes a new numerical strategy that allows for studying the influence of multiple debonding defects when a brittle and ductile adhesive is used. A new nonlinear bond-slip relationship is used and four different ratios between the debonded and the bonded area (η) are assumed: 0%, 25%, 50%, and 75%. The proposed model is based on the Finite Difference Method (FDM) and validation is carried out with a commercial Finite Element Method (FEM) package. The load-slip curves allowed for observing that the proposed FDM and the FEM are consistent and both revealed degradation of the load capacity of the joints with the increase of η. Moreover, by adopting a displacement control at the CFRP-free end, a snap-through and snap-back phenomenon are observed in the specimens with a localized debonding defect.

Effect of acidic environment exposure on mechanical properties of TRM composites

With the increasing application of textile-reinforced mortars (TRMs) for the strengthening of existing masonry structures, knowing the long-term behavior of these composites is increasingly of great importance. In recent years, there has been a progressive research effort on the durability of TRM composites following different aging protocols, yet the durability of TRMs still necessitates comprehensive experimental studies for a better understanding of their behavior. On the other hand, there is also a lack of established aging methods, including acidic attack.The present study aims to leverage knowledge of the durability of TRMs when exposed to acidic attack. For this purpose, two different commercial fabrics made of glass and basalt fibers and a lime-based mortar have been used. In parallel, two aging conditions were also investigated considering 1000, 3000, and 5000 hours of exposure. Overall, a total number of 462 specimens were tested, including tests for the matrix, fabric, and composite. Compressive, flexural, and elastic modulus tests studied the variation in the mechanical properties of mortar, tensile tests focused on the textiles, and pull-out and single-lap shear tests were used for TRM composite’s behavior. To investigate possible changes in material behavior due to aging, mineralogical and chemical analysis including Optical Microscopy, SEM, XRD, and TGA were carried out.

Investigation of mechanical properties of nano hexagonal boron nitride integrated epoxy adhesives in bonded GFRP and CFRP composite joints

In this study, two kinds of fiber reinforced thermoset composites (glass and carbon fiber) were fabricated with almost same volume fraction and thickness and bonded with epoxy adhesives (ADs) with various weight contents of nano hexagonal boron nitride (nano-h-BN) (0, 1, 2 and 3 wt%). The single-lap shear (SLS) tests were conducted on bonded joints with ADs. The effects of nano-h-BN contents on the morphology and micro-structure of the epoxy ADs were studied by scanning electron microscope (SEM). The specimens with the glass fiber reinforced composites with 2-wt% nano-h-BN showed the highest results of SLS strength characteristics with an improvement of 23.6 % and 37.2 % in the SLS strength compared to the specimens with the glass fiber and without nano-h-BN in 0° and 90° directions. Furthermore, the specimens with the carbon fiber reinforced composites with 2-wt% nano-h-BN showed an improvement of 191.7 % and 78.3 % in the SLS strength compared to the specimens with the carbon fiber and without nano-h-BN in 0° and 90° directions.

Mechanical characterization of ultrasonically welded CF/PEEK laminates by short beam shear test

Bond strength between composite plates has often been evaluated using single-lap shear tests, with the difficulty of having the characteristics of the entire bond area reflected in the results. To overcome this limitation, a short-beam shear test was performed in this study. The specimens were fabricated by ultrasonic welding using carbon fiber reinforced polyether ether ketone laminates as the adherend and a resin mesh. The effect on mechanical characterization was investigated by varying the thickness and stacking configuration of the adherend and the welding energy. The highest apparent interlaminar shear strength was observed when an approximately 3 mm thick adherend of the quasi-isotropic laminate was welded, and the strength was approximately 17% lower than that of non-welded laminates.

A novel method for acoustic emission source location in CFRP-concrete debonding using ΔT mapping and DBSCAN algorithm

Concrete-CFRP composite structures exhibit a stiff behavior, leading to sudden failure. Monitoring the brittle nature of this failure is crucial, and the acoustic emission (AE) technique provides a promising tool for locating and classifying damage. However, the conventional source location methodology assumes that the acoustic wave travels in a straight path with constant velocity. This assumption does not hold true for concrete-CFRP composite structures, where the presence of microcracks and CFRP layers induces anisotropy and defects, altering the wave speed and traveling direction. This, in turn, introduces errors in the source location. To address these challenges, this research presents a novel source location method using ΔT maps and achieving convergence through the Density-Based Spatial Clustering of Applications with Noise (DBSCAN) algorithm. The methodology demonstrates significant improvement in AE source location when applied to concrete-CFRP composite specimens in the presence defects with varying magnitudes. Additionally, the proposed method shows effectiveness in monitoring damage progression when applied to single-lap shear tests performed on concrete specimens with attached CFRP laminate.

Multi-objective optimization of rivet and die for self-piercing riveting using finite element analysis

This study numerically investigated the effects of self-piercing riveting (SPR) process parameters on the quality of joints between steel and aluminum alloy sheets. First, the mechanical properties of each metal were experimentally evaluated, and a single-lap shear test was performed to validate a constructed finite element analysis model. This model was subsequently applied to optimize the die depth, die radius, and rivet length parameters of the SPR process using a multi-objective optimization method considering the shear strength, interlocking distance, and minimum thickness of the bottom sheet as objective functions. The results indicated that the maximum interlock distance was achieved with a longer die depth and larger die radius, and the largest minimum thickness of the bottom sheet was achieved with a shorter rivet length and larger die depth and radius. The die radius and depth were determined to be the most critical variables for all objective functions. The findings of this study can be applied to optimize the SPR of steel and aluminum alloy sheets.

A simple and efficient resin precoating treatment on anodised substrate surfaces for enhancing the adhesive bonding strength between aluminium and mild steel

The primary concerns in the adhesive bonding of metal substrate surfaces include inadequate wettability, compatibility, and insufficient mechanical interaction at the bonding interface. These factors are significant barriers to developing and manufacturing high-strength bonded materials. This study utilized three different anodising techniques, such as H3PO4, H2SO4, and NaOH, to produce micro-rough surfaces that improve the adhesive bond between aluminium alloy and mild steel. A novel and a simple method known as resin pre-coating (RPC) were used to increase the wetting and effectively seal the micro-cavities of mild steel and aluminium surfaces. RPC solution comprises 10 wt% resin (Absence of hardener) and 90 wt% acetone, which facilitated the penetration of resin into the microcavities surface, thereby increasing the bonding surfaces. Subsequently, the normal adhesive mixed with hardener is placed onto the metal surfaces. The adhesive bonding strength was evaluated by conducting the single lap shear test under various surface conditions. The surface topography of anodised samples were examined by X-ray Photoelectron Spectroscopy (XPS), Atomic Force Microscopy (AFM), Field Emission Scanning Electron Microscopy (FESEM), and Contact Angle Goniometer. Experimental results of a lap shear test revealed that the adhesive bond strength of H3PO4 anodised samples is greater than those of H2SO4 and NaOH anodised samples. Furthermore, the RPC treatment increased the bond strength of all H3PO4 anodised samples by 46.91–47.26 %, for H2SO4 samples by 39.71–42.22 %, and NaOH samples by 37.89–48.51 %, compared to the readings obtained without RPC treatment. The combined use of H3PO4 and RPC treatment results in the greatest bonding strength of 16.765 MPa, which is 9.17 % and 20.10 % greater than the bonding strength of H2SO4 and NaOH anodised samples. Thus, the H3PO4 anodised method improved the wetting ability of the metal surface and maximized the use of contact area on the rough substrate surfaces. The anodising treatment details in this study are inexpensive and simple for creating strong adhesive joints in aviation, automobile, and aerospace applications.

Effect of anchorages on C-FRCM/concrete interfacial shear performance

In this study, single-lap shear tests were performed on 42 concrete specimens that were reinforced with Carbon Fabric Reinforced Cementitious Matrix (C-FRCM). The interfacial properties were enhanced through the use of fabric end-bending anchorage, a U-shaped hoop, and multiple U-shaped hoops. The bond performance of the C-FRCM/concrete interface was analyzed by examining the failure mode, ultimate stress, and interface slip of the specimens, considering four parameters: bond length of C-FRCM, number of fabric layers, fabric end-bending anchorage, and U-shaped hoop anchorage, as well as their respective mechanisms. The bond-slip constitutive parameters were calculated based on the trilinear cohesive material law and load-displacement simulation curves were obtained for each specimen through numerical simulation, which were in agreement with the test results, verifying the law's validity. Finally, the positive effect of anchorages on the constitutive parameters was analyzed.

Investigation on the joining process and strength of laser circle welding between Al5052 and CFRP dissimilar materials

Laser welding is an effective approach to joining metal and composite. In the present research, laser circle welding was proposed to join the Al5052 sheet and PA6-CFRP as the first try. A process window was suggested according to the welding results and joint appearance. Single lap shear test was employed to evaluate the mechanical performance of welded joints under different welding conditions. The cross-section and fracture surface were subjected to multi-scale characterizations to subdivide the joining zone and understand the joining process. The result showed that 10 sets in 18 groups of welding parameters can achieve successful bonding. The welding results can be classified into four categories: non-connected, aging-failing, effective-joining and burn-through. The joining zone of laser circle welding was divided into three subregions. The adhesive zone (AZ) presented an interfacial fracture while the local failing passed through plastics basement in cohesive (CZ). The overheating of CFRP generated decomposed zone (DZ). The signal peak of O-C=O bond disappeared in the entire joining zone on CFRP sheet and the intensity of carbide was significant in DZ. The laser circle welded joint presented brittle and ductile fracture modes, which were related to the joining zone component. The joining strength can reach about 656 ± 22 N, 2135 ± 331 N and 3223 ± 257 N under one-circle, double-circle and three-circle scanning, respectively. Increased scanning numbers can decrease the required laser power and improve joining strength by extending heating time, while it also increased the risk of burn-through.

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.

Bond behavior of CFRP reinforcement systems with concrete under static and fatigue loading

In this research, the single lap shear tests were used to investigate the bond behavior of carbon fiber reinforced polymer (CFRP) sheets bonded to concrete blocks under static and fatigue loads. The magnitude of the fatigue load was considered as a parameter that varied from a minimum load of 10% of Pu to a maximum load of 60%, 70% and 80% of the ultimate static load. For both loading scenarios, the applied load versus slips curves and the profiles of the interface zone strain were presented. In addition, comparisons, and analyses of the failure mode of samples subjected to static and fatigue loading are presented. The experimental results demonstrate that the loading level has a significant impact on the failure mode, fatigue life and stiffness degradation of CFRP-concrete joints during the fatigue loading.Finally, a prediction model for the fatigue life of the CFRP-concrete joint was developed as part of this investigation.

Strip-based numerical analysis of CFRP-reinforced steel plates with multiple debonding defects using the Runge-Kutta method

In recent years, carbon fiber-reinforced polymers (CFRP) have earned extensive attention in the field of structural rehabilitation. Adhesive bonding, as a prevalent technique, plays a crucial role in utilizing CFRP for strengthening steel structures. Nevertheless, debonding defects, commonly arising within the bond region between CFRP and host structures, hold the potential to induce the premature debonding failure of adhesively bonded joints. As a result, this research attempts to propose a strip-based numerical method using the explicit 4th-order Runge-Kutta technique (strip-based RK4) to investigate the full-range bond behavior of CFRP-to-steel single-lap joints with multiple arbitrary debonding defects. Also, three-dimensional (3D) finite element models (FEMs) of fully bonded single-lap joints were established in conjunction with cohesive zone modeling (CZM) to simulate the single-lap shear test reported in literature, based on which joints containing debonding defects were further modeled. Predictions from the proposed methodology were subsequently compared with test results and FE analysis to confirm its accuracy. Thereafter, the parametric analysis was carried out to investigate the effects of parameters, including bond length and defect position, on the bond behavior of the single-lap joint. The results indicate that the proposed strip-based RK4 method is accurate, with errors within 2% compared to FE analysis, and computationally efficient, with runtime being less than 50% of FE analysis. The findings of this study can be used as a guide for the design or damage assessment of CFRP-repaired structures in the future.