Single Lap Shear Research Articles

Enhancing resistance welding strength of carbon fiber/polycaprolactam thermoplastic composites through coupling agent‐modified metal heating elements

AbstractThis study investigates the impact of coupling agent‐modified resistance welding heating elements on the welding strength of carbon fiber‐reinforced polyamide 6 (PA6) thermoplastic composites. Silane coupling agent KH550 and titanate coupling agent UP‐201 were used to modify heating elements made of 304 stainless steel mesh. Optimal modification parameters for KH550‐modified stainless steel mesh (SSM) were determined using orthogonal experiments, resulting in maximum single lap shear strength (LSS) of 17.05 MPa under specific welding conditions. Comparative tests demonstrated the enhancement effect of UP‐201‐modified SSM on LSS. Additionally, two experimental schemes were used to study the synergistic enhancement effect of KH550 and UP‐201 on the LSS of resistance welded joints. The findings indicate that both coupling agents improve the welding strength, with significant differences in their individual and combined effects.Highlights This study explores carbon fiber reinforced Nylon 6, an innovative thermoplastic. Analyzed effects of modified heating elements on joint shear strength. Examined silane and titanate coupling agents' effects on weld joint shear strength. Investigated synergistic effects of silane and titanate agents on weld joint strength. Investigated the synergistic enhancement mechanism of silane and titanate agents.

On the Influence of Welding Parameters and Their Interdependence During Robotic Continuous Ultrasonic Welding of Carbon Fibre Reinforced Thermoplastics

Ultrasonic welding of fibre-reinforced thermoplastics is a joining technology with high potential for short welding times and low energy consumption. While the majority of the current studies on continuous ultrasonic welding have so far focused on woven reinforcements, unidirectional materials are preferred for highly loaded aerospace components due to their better mechanical performance. Therefore, this paper investigates the influence and interdependence of the welding speed, amplitude, and energy director thickness on the weld quality of adherends made of unidirectional composites. The quality of the welded joints is assessed by a single-lap shear strength and fracture surface analysis complemented by the microscopic analysis of cross-sections and comparison to a co-consolidated reference. The results showed that the welding process is highly affected by changing welding speeds for a given amplitude. Furthermore, while lower amplitudes lead to significant scatter in the welding quality, higher amplitudes result in increased heating rates and a fully molten energy director even for high welding speeds. Nevertheless, insufficient consolidation at high welding speeds results in porosity in the weld line. Finally, it was observed that thicker, and therefore more compliant, energy directors lead to more uniform melting of the energy director and less deviation in the weld quality for a wider range of welding speeds.

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.

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.

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.

Improving the joint strength of thermoplastic composites joined by press joining using laser-based surface treatment

Fibre-reinforced thermoplastic composites (TPC) provide an automated and cost-effective solution for their use in lightweight structures in series production. The combination of different material configurations allows the design of highly stress tolerant components. Previous studies demonstrated that the combination of TPC sheets, TPC hollow profiles and injection moulding compounds is even suitable for crash-relevant automotive parts. All three components are combined during the injection moulding process. To prevent collapse, the part must remain in a consolidated state and cannot be preheated. However, this results in poor adhesion between the hollow profile, the bulk material, and the TPC sheet. Previous studies have shown that the bonding strength between the hollow profile and the injection moulding compound can be increased by surface pre-treatment using laser structuring and plasma technology. In this work, laser structuring is employed to enhance the bonding strength between the hollow profile and the TPC sheet. Microscopy analysis is used to investigate the resulting surface morphology. Subsequently, single-lap-shear (SLS) specimens are produced by pressing the TPC sheets onto the flat part. The resulting bonding strengths are then evaluated by tensile shear tests. The study analyses the impact of various pre-treatment parameters on the bonding strength. Furthermore, it investigates the effect of sheet temperature on the bonding strength, including specimens without pre-treatment. Finally, the results of the surface treatment of hollow composite profiles are discussed.

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.

Curing and Failure Monitoring of Composite Material Single-Lap Joint Based on CNT/PSF Sensor

Abstract Composite bonded structures are widely used in the field of aerospace. The safety of composite structures can be ensured by the health monitoring and early warning of their whole life. In this paper, a composite CNT/PSF film sensor based on asymmetric porous PSF film was designed and prepared. Through integrated molding with epoxy film, in-situ monitoring of gel point (142.1°C) and curing time (36min) of epoxy film is realized. After optimization of curing process, tensile strength of epoxy film casting body is increased by 86.3%. The single lap shear strength of the composite is increased by 45.7%. The CNT/PSF film sensor with composite material has high response sensitivity (GF≈1.4) and linearity (0.998) to cyclic strain (0-3000με). In the shear experiment of composite single lap joint, the adhesive layer presents a typical cohesive failure mode of first compression, then tensile and finally failure. The resistance changes of CNT/PSF film sensor first decreases from 0 to -1‰, and then rises to 2.7‰. Finally, the fracture response is good, and the in-situ failure behavior monitoring of the joint can be fully realized.

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.

Effect of Mo and ZrO2 nanoparticles addition on interfacial properties and shear strength of Sn58Bi/Cu solder joint

The influence of Mo and ZrO2 nanoparticles addition on the interfacial properties and shear strength of Sn58Bi solder joint was investigated. The interfacial microstructures of Sn58Bi/Cu, Sn58Bi + Mo/Cu and Sn58Bi + ZrO2/Cu solder joints were analysed using a scanning electron microscope (SEM) coupled with energy dispersive X-ray (EDX) and the X-ray diffraction (XRD). Intermetallic compounds (IMCs) of MoSn2 are detected in the Sn58Bi + Mo/Cu solder joint, while SnZr, Zr5Sn3, ZrCu and ZrSn2 are detected in Sn58Bi + ZrO2/Cu solder joint. IMC layers for both composite solders comprise of Cu6Sn5 and Cu3Sn. The SEM images of these layers were used to measure the IMC layer’s thickness. The average IMC layer’s thickness is 1.4431 µm for Sn58Bi + Mo/Cu and 0.9112 µm for Sn58Bi + ZrO2/Cu solder joints. Shear strength of the solder joints was investigated via the single shear lap test method. The average maximum load and shear stress of the Sn58Bi + Mo/Cu and Sn58Bi + ZrO2/Cu solder joints are increased by 33% and 69%, respectively, as compared to those of the Sn58Bi/Cu solder joint. By comparing both composite solder joints, the latter prevails better as adding smaller sized ZrO2 nanoparticles improves the interfacial properties granting a stronger solder joint.

Bio‐composite using polyhydroxyalkanoates and sustainable nanofillers derived from cellulose nanofibers and its application for an environmentally friendly packaging material

AbstractPolyhydroxyalkanoates (PHA) is a carbon neutral material that contributes to reducing greenhouse gas emissions due to manufactured from biomass and easily degraded by the enzymatic effects of microorganisms in the natural environment. However, PHA exhibits poorer mechanical properties and processability compared with petroleum‐based plastics. This study used cellulose nanofiber (CNF) to improve limit of PHA. Moreover, CNF was silylated to reduce polarity difference with PHA and enhance the dispersibility of nanocellulose at PHA. At a result, the silylation process was successfully performed by Si‐CH3 stretching peaks in Fourier transform infrared spectroscopy spectra and hydrophobicity of TEOS‐MTES‐CNF (TECNF) was confirmed by observed water contact angle (147°). In addition, nanostructure of TECNF was maintained during silylation and drying process through field emission scanning electron microscopy. Moreover, the PHA/TECNF composite showed enhanced processability, and tensile strength was increase almost 37% (0.52 MPa) compared with PHA. Oxygen transmission rates (300 cc/m2۰day) and single lap shear strength (225 kPa) were determined to be at least equivalent or superior to those of commercial packaging materials. Therefore, TECNF could be considered as a reinforcing agent, nucleating agent, and plasticizer in PHA. Also, this composite has possibilities to using as environmentally friendly packaging materials.

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.

Investigation on the Thermal and Wettability Properties Aided with Mechanical Test Simulation of Tin (Sn) - Bismuth (Bi) Solder Alloy at Low Reflow Temperatures

The current study proposes to investigate the thermal, wettability and mechanical properties of a low temperature SnBi solder. The main aim is to investigate the performance of the SnBi solder alloy with different Bi composition. The study also establishes the relationship between melting temperature, spreading area and tensile stress of the SnBi with different Bi composition at different low reflow temperatures. The thermal and wettability tests are conducted experimentally, while the mechanical test will be analysed via finite element analyses (FEA). The single shear lap test method was adopted for the simulation. The thermal properties of the SnBi solder are investigated using the differential scanning calorimeter (DSC). The reflow temperature selected ranges from 160 °C to 220 °C to accommodate the purpose of low temperature soldering. Wetting test results showed that spreading area of Sn48Bi solder alloy increased to 28.1 and 42.88 at 180 °C and 210 °C respectively. The increase in the Bi composition reduced the tensile strength regardless of the increase of the reflow temperature. The preliminary results commend the characteristics of the SnBi solder as a possible alternative to the Pb solder.

Effect of the percentage of MUF adhesive coverage on shear strength when bonding different wood species

Due to climate changes, it is necessary to consider the use of other wood species to replace currently used woods. This work deals with the determination of the shear strength of bonded veneers (eight European wood species: spruce, larch, pine, beech, oak, poplar, birch, and alder) with Silekol® 311 melamine-urea-formaldehyde adhesive (MUF) with a variable coverage on the surface of the samples: 10, 15, 20, 25, 30, 50, 75, and 100%. The Automated Bonding Evaluation System (ABES) was used to evaluate and compare adhesive bond strengths. The larch, beech, and oak samples exhibited greater single-lap shear strength than the control samples from spruce. There was no statistically significant difference in shear strength regarding the adhesive coverage from 100% to 20% on the surface of the samples, for almost all wood species. The results of the project provide basic information about the bonding strengths with different coverage in the adhesive layer, comparing non-commonly used wood species in wood-based composites such as oriented strand board and particleboard.

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.

Improved mechanical and fire-retardant properties of fiber-reinforced composites manufactured via modified resins and metallic thin films

Fiber-reinforced polymeric composites have been extensively used in different industrial applications because of their excellent mechanical and other properties but have lower tolerance levels for fire and lightning damage. The thermal, mechanical, and electrical conductivity of these composites can be substantially increased using some thin metallic films for higher fire resistance. The objective of this study was to develop fire-retardant fiber-reinforced composites using modified resins and metallic copper (Cu) thin films and test and characterize the mechanical and thermal properties of these prepared composites. Standard hand wet layup process was used to manufacture composite panels, and then the flame retardant and other physical and chemical properties were determined before and after resin modification and surface metal film coatings. These modified resins and the conductive metallic films of the composite provided superior flame retardancy and higher mechanical strength. The prepared composite panels made from modified epoxy via 9,10-dihydro-9-oxo-10-phosphaphenanthrene-10-oxide (DOPO) inclusion and with metallic surface coatings passed the UL-94 vertical flame testing with a V-0 rating. This composite achieved an average flexural strength of 344.2 MPa, a mean tensile strength of 400.82 MPa, and a shear strength of 6.54 MPa for single lap shear joint studies. Fractography results also show better bonding of the matrix and fiber with no significant damage. This study may open new opportunities in various composite industries.