Effect of Nanoclay Incorporation on the Impact Properties of Adhesively Bonded Composite Structures

During manufacturing or service conditions, adhesively bonded composites are often subjected to impact. This impact may result in a reduction in strength and structural integrity of engineering components that are composed of adhesively bonded composite structures. The investigation of the degradation of strength of structural joints is, therefore, of paramount importance for their successful performance. Impact resistance of bondline in adhesively joined composites can be altered by the addition of nanoclay in the adhesive during fabrication of adhesive joints. In this study, impact test was carried out on graphite–epoxy composite panels bonded with nanoclay adhesive at different impact energies using drop-weight impact test equipment. Adhesive joints were fabricated by adding nanoclay in volume fractions of 1, 2 and 5% in the adhesive bondline. For comparison, plain adhesive joints were fabricated without nanoclay incorporation in the bondline. Impact testing was performed on these joints at 5, 10 and 20 J, to study the effect of inclusion of nanoclay in the epoxy adhesive. In order to determine the flexural load bearing capacity and stiffness reduction after impact, a three-point bending test was conducted on unimpacted and impacted specimens. The results showed that there was an improvement in impact capacity, however there was a reduction in flexural strength due to nanoclay incorporation.     

Influence of Fabrication Residual Thermal Stresses on Rubber-toughened Adhesive Tubular Single Lap Steel-Steel Joints under Tensile Load

The tensile load bearing capability of adhesively-bonded tubular single lap joints which is calculated under the assumption of linear mechanical adhesive properties is usually much less than the experimentally-determined because the majority of the load transfer of adhesively-bonded joints is accomplished by the nonlinear behavior of rubber-toughened epoxy adhesives. Also, as the adhesive thickness increases, the calculated tensile load bearing capability with the linear mechanical adhesive properties increases, while, on the contrary, the experimentally-determined tensile load bearing capability decreases.

In this paper, the stress analysis of adhesively-bonded tubular single lap steel-steel joints under tensile load was performed taking into account the nonlinear mechanical properties and fabrication residual thermal stresses of the adhesive. The nonlinear tensile properties of the adhesive were approximated by an exponential equation which was represented by the initial tensile modulus and ultimate tensile strength of the adhesive.

Using the results of stress analysis, the failure criterion for the adhesively-bonded tubular single lap steel-steel joints under tensile load was developed, which can be used to predict the load-bearing capability of the joint. From the failure criterion, it was found that the fracture of the adhesively-bonded joint was much influenced by the fabrication residual thermal stresses.     

Strength Analysis of Adhesively-Bonded Tubular Single Lap Steel-Steel Joints Under Axial Loads Considering Residual Thermal Stresses

The static tensile load bearing capability of adhesively-bonded tubular single lap joints calculated using linear mechanical adhesive properties is usually far less than the experimentally-determined one because the majority of the load transfer of adhesively-bonded joints is accomplished by the nonlinear behavior of the rubber-toughened epoxy adhesive

In this paper, both the nonlinear mechanical properties and the residual thermal stresses in the adhesive resulting from joint fabrication were included in the stress calculation of adhesively-bonded joints. The nonlinear tensile properties of the adhesive were approximated by an exponential equation which was represented by the initial tensile modulus and ultimate tensile strength of the adhesive.

From the tensile tests and the stress analyses of adhesively-bonded joints, a failure model for adhesively-bonded tubular single lap joints under axial loads was proposed.     

Similarity Concepts in the Fatigue Fracture of Adhesively Bonded Joints

Cyclic debond data obtained from fatigue testing of four different specimen geometries having the same adhesive is considered. Fatigue properties of the adhesive are characterized in terms of linear elastic fracture mechanics concepts whereby debond growth rates are correlated to appropriate mixed mode fracture parameters. Stress analyses of the four specimens under maximum load indicate that in most cases inclusion of geometric nonlinearities is required for the determination of the fracture parameters. For three of the specimens considered, the debond growth laws based on total energy release rate as correlating mixed-mode fracture parameter were found to be similar. A number of potential reasons for the lack of similarity in debond growth laws in all four specimens are explored.     

Low‐velocity impacts in continuous glass fiber/polypropylene composites

The low‐velocity impact behavior of a continuous glass fiber/polypropylene composite was investigated. Optical microscopy and ultrasonic scanning were used to determine the impact‐induced damage. At low impact energy, the predominant damage mechanism observed was matrix cracking, while at high energy the damage mechanisms observed were delamination, plastic deformation, which produced a residual specimen curvature, and a small amount of fiber breakage at the edge of the indentation on the impacted face of the specimens. The impact load vs. time signals were recorded during impact and showed that the load corresponding to the onset of delamination was independent of the impact energy in the range tested. The load at which the onset of delamination occurred corresponded to the values obtained by performing a linear regression of the delaminated area, obtained by ultrasonic scanning, as a function of the impact force. Tensile and flexural tests performed on impacted specimens showed that the tensile and flexural residual strengths and the flexural modulus decreased with increasing incident impact energy, while the post‐impact residual tensile modulus remained constant. The dynamic interlaminar fracture toughness was evaluated from the critical dynamic (impact) strain energy release rate of specimens with a delamination simulated by an embedded insert. The results are compared with the interlaminar fracture toughness values obtained during subcritical steady crack growth.     

Controlled reduced-strength epoxy-aluminium joints validated by ultrasonic and mechanical measurements

In this study a series of joint systems, consisting of aluminium substrates bonded using an epoxy adhesive, were produced. Several levels of adhesion were achieved by altering the substrate surface treatment and the curing cycle of the adhesive. The goal of this study was to produce reduced-strength epoxy-aluminium joints that could be used as reference samples for ultrasonic non-destructive testing (NDT) studies. There is clearly a continuing challenge to improve the quality of the adhesively-bonded joint inspection to ensure the durability of the bonds, to monitor repairs, and to evaluate the strength of the bonds. However, developing and qualifying innovative or advanced non-destructive testing requires an essential preliminary step: a method for repeatedly producing reduced-strength bonded test specimens must be developed. In this study, in addition to a rigorous protocol to produce bonded joints, complementary ultrasonic CSCAN were realised to validate the homogeneity of the joints and to ensure that samples met all requirements so as to be considered as reference samples. Mechanical tests were performed to evaluate the mechanical strength of each joint and Acoustic Emission (AE) was used during the tests in order to confirm the expected fracture mechanisms.     

Failure behaviour of the single lap joints of angle-plied composites under three point bending tests

Abstract

In this paper, the response of adhesively-bonded single lap joints (SLJs) with angle-plied composite adherends subjected to flexural loading was investigated. The experiments were carried out for the adherends, glass reinforced polymer matrix, with three kinds of stacking sequence. A three-dimensional finite element (FE) model was developed using ABAQUS/Explicit. The three dimensional Hashin failure criterion with an appropriate damage evolution law was used to characterize the damage inside a ply. Cohesive zone elements were used to model the damage in the adhesive layer (AF163-2K) and the interply failure, that is, the delamination. The developed numerical model was verified with the performed experiments. The SLJs of [±20]_5s and [±45]_5s failed due to failure in the adhesive layer and the delamination between the plies, whereas that of [±10]_5s failed mainly due to the former failure. The intralaminar damage was not noticed for any case. The influence of the fiber angle of plies in the adherends, adherend thickness, overlap length, and the thickness of adhesive layer on the damage in the adhesive layer and the delamination were investigated in terms of the competition between these two failures and activation of different failure modes in each thoroughly.     

Strength of Adhesively-Bonded Butt Joints of Tubes Subjected to Combined High-Rate Loads

The dynamic strength of adhesively-bonded joints was investigated experimentally. The strength of the bonded joints under combined high rate loading was measured using the clamped Hopkinson bar method. Tubular butt joints bonded by epoxy resin were used for the experiment. Combined stress waves of tension and torsion were applied to the specimens. The strength of the adhesively-bonded joint was determined by measuring the stress waves propagated in the load output tube of the specimen. It was found that the dynamic strength of the adhesive joints was greater than the static strength under tensile and shear load.     

Debond and failure characteristics of a double-lap adhesively bonded joint

A novel double-lap joint design was used to bond steel adherends using a structural epoxy adhesive. Different levels of debond were built into the joint using a mold release agent during fabrication. The damping capacity measurements of the debonded specimens were obtained using a FFTbased impulse-frequency response vibration technique. The joint strengths were obtained by loading the specimens to failure in a servo-hydraulic MTS 850 test system. It was observed that the failure strength of the joint correlated well with the loss factor (a measure of damping). Empirical equations for predicting the strength of the joint in terms of the loss factor or resonant frequency are presented. A torsional vibration test rig was also used to evaluate the damping properties and to predict the mechanical properties of the bulk adhesive used in the fabrication of the adhesive joint. SEM fractographs of both the bulk adhesive specimen and the debonded joints are examined and the modes of failure presented.     

Ultrasonic machining of alumina-based ceramic composites

In ultrasonic machining (USM), the material is removed primarily by repeated impact of the abrasive particles, and the material removal rate (MRR) and surface integrity are influenced by various factors including the material parameters of the workpiece materials. In this study, effect of the properties and microstructure of the workpiece materials on the MRR in ultrasonic machining of alumina-based ceramic composites was investigated. The distributions of strength of the ultrasonic machined specimens were used to evaluate the surface integrity. Results showed that fracture toughness of the ceramic composite played an important role with respect to MRR. In USM of whisker-reinforced alumina composites, the MRR depended on the whisker orientation. Studies of strength distributions of alumina-based ceramic composites machined by USM demonstrated that the flexural strength varied narrowly from the mean value, and the composites with high fracture toughness showed higher Weibull modulus.     

Fatigue lifetime assessment of adhesive joints by ultrasonic and thermal wave imaging

Various nondestructive evaluation (NDE) methods are frequently employed to inspect the adhesive bonds of aircraft structures in service. The literature on the capability of various NDE techniques reveals a deficiency in linking NDE test parameter characteristics of the frequency or size of defects to critical failure properties such as the lifetime and the strength of adhesive bonds. In this study an attempt has been made to develop such correlations. A specimen geometry was employed so as to permit cleavage-type debonding under fatigue loading. This geometry and loading configuration provide for a simple fatigue testing program and simple analytical methods. Damage by flexural fatigue aging of these adhesively bonded specimens was induced at different intervals of their fatigue lifetime. The specimens were composed of materials that were commonly used in actual aircraft production during the 1970s. Pulse-echo ultrasonic C-scanning and thermal wave imaging were performed to inspect the adhesive joints at various percentages of the fatigue lifetime. A novel low-frequency ultrasonic method was used for making the C-scans; this technique was immune to signal amplitude changes due to interference phenomena caused by bond thickness variation. A direct correlation of the ultrasonic parameter (size of the debonded area) with the percentage lifetime of the adhesive joints was tentatively established. It was also found that this correlation was consistent when the scanning was conducted from either the top surface or the bottom surface of the adhesive joints. A similar correlation between the size of the debonded area and the percentage of fatigue lifetime of the adhesive joint was found using thennal wave imaging. Thus, it appears that the measurements obtained from both techniques are consistent.     

机织/针织混合铺层对复合材料力学性能的影响

为使纺织复合材料同时具有机织结构复合材料和针织结构复合材料的综合力学性能,通过混合铺层方式制备机织/针织混合结构复合材料。以芳纶机织平纹织物和针织罗纹织物为增强体,以环氧树脂为基体,调整复合材料中增强体的铺层顺序,利用真空辅助成型技术制备四层层压机织/针织混合结构复合材料。通过对复合材料拉伸性能、弯曲性能和冲击性能的测试,分析混合铺层和铺层顺序对芳纶环氧树脂复合材料力学性能的影响。结果表明,混合铺层和铺层顺序对芳纶环氧树脂复合材料的弯曲强度和冲击强度有较大影响,特别是对罗纹结构复合材料纬向弯曲强度和冲击强度的改善。当采用相同铺层方式,罗纹织物为受力面时,机织/针织混合结构复合材料具有较大弯曲强度和冲击强度。     

Impact response of adhesive reversible joints made of thermoplastic nanomodified adhesive

The impact response of a reversible adhesive joint is experimentally assessed in this work. Joint reversibility is improved with a system that uses nanomodification of the thermoplastic adhesive used for bonding plastic components. This system, coupled with electromagnetic induction, is able to guarantee the separation of joints without any damage to the substrates. Drop dart tests at different impact velocities are carried out on neat and nanomodified bonded joints in order to compare the impact behavior before and after the introduction of nanoparticles. Experimental results show that the impact response, assessed in terms of peak load, absorbed energy, and flexural stiffness, can be affected by the introduction of nanoparticles. This work shows that adhesive nanomodified joints represent an effective and applicable solution for the reversible assembling of semi-structural components subjected to low-velocity impact loads.     

Application of bi-adhesive in double-strap joints subjected to bending moment

Generally, all failures in adhesively-bonded joints begin at the overlap ends because of the stress concentration occurring at the ends. The approach which reduces stress concentration at the overlap ends increases the load capacity and delays the failure. The lower the stiffness of the adhesive used, the lower the stress concentration, and the lower stress concentration gives rise to higher joint strength. In this work, the results of the application of two adhesives, one stiff and one flexible, with very different mechanical behaviors along the overlap length in double strap joints subjected to bending moment, were analyzed. A stiff adhesive was applied in the middle portion of overlap, while a flexible adhesive was applied towards the edges. The results show that the bi-adhesively-bonded joints carry more loads and have higher strength when compared with single-adhesively-bonded joints.     

The Effect of Surface Preparation and Exposure Environment on the Bond Failure Processes in Adhesively Bonded Sheet Molded Composite (SMC)

The durability of adhesively-bonded composites has been investigated using a wedge-type specimen. Polyester-resin, fiberglass sheet molded composite (SMC) was bonded with a commercial two-part poly-urethane adhesive. The SMC composite received one of four different surface preparations: no treatment, abrasion, priming, or abrasion and priming. The wedge test was used to study the durability of the samples which were exposed to air and to the vapor above water, concentrated ammonium hydroxide, or methanol at 60[ddot]C. The crack length was measured during the experiments. The crack growth rate as a function of surface treatment varied in the manner: untreated ≈ abraded > primed ≈ abraded and primed. The crack growth rate as a function of vapor changed in the manner: methanol > ammonium hydroxide > water ≈ air. The samples were removed at the conclusion of the test and the failure mode was determined visually, by scanning electron microscopy (SEM), and by X-ray photoelectron spectros-copy (XPS). Initial insertion of the wedge resulted in substrate failure (delamination of the composite). Exposure of untreated and abraded samples under stress to the test vapors promoted adhesive failure. Primed and abraded/primed samples under stress and exposed to methanol vapor debonded via cohesive processes.     

Flexural behavior of metallic fiber-reinforced adhesively bonded single lap joints

Incorporation of additives into the adhesive layer in adhesively bonded joints can improve the stress distriution in the adhesive layer and increase adhesive toughness. In this paper, the geometric and material parameters of metal fibers utilized for strengthening adhesively bonded single lap joints under flexural loading were investigated by using experimental investigations and finite element modeling. According to the experimental results, incorporating metal fibers in the adhesive layer of a bonded joint can have a significant impact on the flexural load bearing of the joint. This was in relationship with the numerical results foreseeing enhanced stress distributions of the adhesive layer, when the metal fibers were added to the adhesive layer. Some important parameters in the design of metal fiber-reinforced adhesive joints include the volume fraction (the distance between the fibers and the fiber diameter), orientation, and mechanical properties of the fibers. It was concluded that the peak normal stresses in the adhesive layer can be reduced, and consequently the load bearing of the joint can be improved by reducing the distance between the fibers, increasing the fiber diameter and choosing a stiffer material for the fibers in the longitudinal direction.     

Effect of Adhesive Ductility on Cyclic Debond Mechanism in Composite-to-Composite Bonded Joints

An investigation of an adhesively bonded composite joint with a brittle adhesive was conducted to characterize both the static and fatigue debond growth mechanism under mode I and mixed mode I-II loadings. The bonded system consisted of graphite/epoxy adherends bonded with FM-400 adhesive. Two specimen types were tested: (1) a double-cantilever-beam specimen for mode I loading and (2) a cracked-lap-shear specimen for mixed mode I-II loading. In all specimens tested, failure occurred in the form of debond growth either in a cohesive or adhesive manner. The total strain-energy-release rate is not the criterion for cohesive debond growth under static and fatigue loading in the birttle adhesive as observed in previous studies with the ductile adhesives. Furthermore, the relative fatigue resistance and threshold value of cyclic debond growth in terms of its static fracture strength is higher in the brittle adhesive than its counterpart in the ductile adhesive.     

Tailoring of bonded composite scarf joint interface for impact damage mitigation and stiffness compatibility

A novel composite scarf joint is successfully fabricated with thermoplastic core shell microparticles incorporated into the interlaminar interface regions with a dual objective of mitigating the impact damage and improving the stiffness compatibility of the joint. The impact analysis of the joints revealed that the incorporation of microparticles led to a significant improvement of the impact load bearing capacity of joint and reduced the extent of the damage area. It is also observed from flexural tests that the microparticles reduces the stiffness of the laminate proportional to the weight fraction of the particles and thereby help design a joint adherend with controlled matching stiffness. This engineered scarf joint adherend configuration has the potential to minimise stiffness mismatch between a fatigue worn-out damaged composite part and the new scarf repair patch laminate designed for it. This shall help ensuring an easy restoration of uniform load distribution in the newly bonded composite scarf joints and repairs.     

环氧树脂／凹凸棒土复合材料的分散和力学性能研究

采用超声分散和溶液共混的方法制备环氧树脂/凹凸棒土复合材料。电子显微镜和元素分析的结果表明，超声分散和凹凸棒土的有机化处理可以改善凹凸棒土的团聚状况和亲油性。选用超声波的作用功率为400W，作用时间为5min时的分散条件，复合材料的冲击强度、弯曲强度和弯曲模量均高于环氧树脂，表明凹凸棒土在复合材料中起到了增强的作用。     

平纹编织碳纤维增强碳化硅复合材料低速冲击特性及冲击后的压缩强度

采用落锤冲击试验系统对平纹编织碳纤维增强碳化硅复合材料平板试样进行低速冲击,冲击能量为1.5～9J。冲击试验后,采用超声C扫描得到冲击损伤的大小。对含冲击损伤的试样进行压缩试验,通过与未冲击试样的压缩强度比较,得到冲击试样的剩余压缩强度。并对比了编织陶瓷基复合材料和树脂基复合材料的损伤阻抗和损伤容限。结果显示:随着冲击能量的增加,冲击力峰值、复合材料损伤面积和凹坑深度明显增加,到达峰值冲击力的时间减小。冲击能量的增加会导致冲击损伤面积的增加,而损伤面积的增加会导致剩余压缩强度的明显降低。相对于编织纤维增强树脂基复合材料,编织纤维增强陶瓷基复合材料的损伤阻抗较低,但损伤容限较高。