Prestressed bonded strengthening for structures employing iron-based shape memory alloy (Fe-SMA) has been proven promising. Analyzing adhesively bonded joints necessitates a thorough understanding of the bond-slip behavior. However, when examining the bond-slip behavior of Fe-SMA-to-steel joints comprising nonlinear adhesives, the “forward” and “backward” post-processing methods, representing the current state-of-the-art, produce a trilinear and a trapezoidal bond-slip pattern, respectively, which is inconsistent. To address this inconsistency, the current study investigates the bond behavior of Fe-SMA-to-steel joints, with a particular focus on the bond-slip behavior. Two finite element (FE) joints, one featuring a linear adhesive and the other comprising a nonlinear adhesive, are modeled and compared against physical tests from literature. The “forward” and “backward” processing methods are used to analyze the bond behavior of the two FE joints. Eventually, the aforementioned inconsistency is resolved; a triangular and a trapezoidal bond-slip pattern are characterized for Fe-SMA-to-steel lap-shear joints with linear and nonlinear adhesives, respectively. The trilinear bond-slip behavior is concluded as a result of error accumulation and propagation during the “forward” processing. A hybrid post-processing method, which takes the advantages of both the “forward” and “backward” processing methods, is further proposed for inferring the full-range behavior; the resulting experimental behaviors closely align with simulations using a trapezoidal bond-slip model as input. A comparison against carbon fiber reinforced polymer (CFRP) lap-shear joints demonstrates similar bond-slip characteristics between Fe-SMA and CFRP lap-shear joints.
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