How defects in an adhesive layer influence the fatigue strength of bonded steel-sheet specimens

Fatigue specimens were manufactured with a number of artificial bond defects. The defects were different configurations of non-bonded areas within the nominally perfectly-bonded region. These defects included variants with a reduced degree of bond filling, bonds with a channel without adhesive, zig-zag-shaped bond edges, and finally bond areas with smooth corners. Fatigue testing was performed with the bond loaded in the peel mode. The stiffness was measured for the bonds and was found to vary significantly with defect type and size. The fatigue strength was also found to differ substantially for different bond defects. A finite element model combined with fracture mechanics was used to predict the stiffness drop during fatigue testing of the bonded specimens and to predict fatigue life. The effect of defects in the bond on the stiffness and life was predicted in a satisfactory way.     

Tapered beam on elastic foundation model for compliance rate change of TDCB specimen

A modified beam theory is developed to predict compliance rate change of tapered double cantilever beam (TDCB) specimens for mode-I fracture of hybrid interface bonds, such as polymer composites bonded to wood. The analytical model treats the uncracked region of the specimen as a tapered beam on generalized elastic foundation (TBEF), and the effect of crack tip deformation is incorporated in the formulation. A closed-form solution is obtained to compute the compliance and compliance vs. crack length rate change. The present TBEF model is verified with finite element analyses and experimental calibration data of compliance for wood-wood and wood-composite bonded interfaces. The compliance rate change can be used with experimental critical fracture loads to determine the respective critical strain energy release rates or fracture toughness of interface bonds. The present analytical model, which accounts for the crack tip deformation, can be efficiently and accurately used for compliance and compliance rate-change predictions of TDCB specimens and reduce the experimental calibration effort that is often necessary in fracture studies. Moreover, the constant compliance rate change obtained for linear-slope TDCB specimens can be applied with confidence in mode-I fracture tests of hybrid material interface bonds.     

Apparent interfacial failure in mixed-mode adhesive fracture

Aluminium-epoxy adhesive specimens constructed with the bond at 45? to the direction of loading appear to fail very close to the interface. The actual locus of failure was investigated by¹⁴C labelling of the epoxy polymer and also by Auger spectroscopy profile analysis. Both techniques indicated a residual film of polymer a few hundred angstroms thick on the aluminium surface. The fracture energy of these specimens was determined and found to be affected by the surface roughness of the aluminium. The mixed-mode fracture energy (G _{I,II) C} ^45° of these specimens in the absence of any surface roughness effect (polished surfaces) was 140 J m^?2 compared to 136 J m^?2 for the same polymer in simple opening-modeG _{I C} adhesive fracture. The “interfacial” failure and the effect of surface finish on fracture are discussed in terms of the applied stress directing the failure toward the interface but the approach of the crack to the boundary being limited by the size of the crack tip deformation zone.     

Micromorphological studies of surface densified wood

Scots pine (Pinus sylvestris L.) wood was surface densified in its radial direction in an open press with one heated plate to obtain a higher density on the wood surface whilst retaining the overall thickness of the sample. This study investigated the effect of temperature (100, 150 and 200 °C) and press closing speed (5, 10 and 30 mm/min, giving closing times of 60, 30 and 10 s, respectively) on the micromorphology of the cell-wall, as well as changes occurring during set-recovery of the densified wood. The micromorphology was analysed using scanning electron microscopy (SEM) combined with a sample preparation technique based on ultraviolet-excimer laser ablation. Furthermore, the density profiles of the samples were measured. Low press temperature (100 °C) and short closing time (10 s) resulted in more deformation through the whole thickness, whilst increasing the temperature (150 and 200 °C) and prolonging the closing time (30 and 60 s) enabled more targeted deformation closer to the heated plate. The deformation occurred in the earlywood regions as curling and twisting of the radial cell-walls, however, no apparent cell-wall disruption or internal fracture was observed, even at low temperatures and fast press closing speed, nor after soaking and drying of the samples. In the SEM-analysis after soaking and drying, it was noticed that the cells did not completely recover their original form. Thus, part of the deformation was considered permanent perhaps due to viscoelastic flow and plastic deformation of the cell-wall components.     

Assuring successful bonding to carton boards

This paper considers the factors that will influence successful adhesive bonding to carton-boards. Although the paper assumes the use of carton-board within the packaging industry, the majority of the arguments may be applied to other bonding applications. The commonest adhesive types used within the packaging industry for carton-boards are PVA-type emulsion and hot-melts. Other adhesives used will include animal glues, starches and dextrines, acrylics etc. Although these adhesives vary considerably in properties they share the majority of requirements for successful bonding. The paper firstly considers bond structure and the basic modes of bond failure. It is surprising how often these are misunderstood or ignored when bonding problems occur. An inspection of the precise nature of a bond failure often suggests the cause of the problem, and at least eliminates a number of possible causes. The paper then discusses the properties required of boards, board surfaces (be they printed, varnished, coated or otherwise) and adhesives for the successful manufacture of bonds. Techniques for evaluating trial bond performance and, finally, the need for good 'housekeeping' are considered.     

Observation of deformation and damage at the tip of cracks in adhesive bonds loaded in shear and assessment of a criterion for fracture

The evolution of damage at the tip of cracks in adhesive bonds deforming in shear was monitored in real time using a high-magnification video camera. Brittle and a ductile epoxy resins were evaluated, with the bond thickness t being an experimental variable. An extensive zone of plastic deformation developed ahead of the crack tip prior to fracture. In the case of the brittle adhesive, for relatively thick bonds tensile microcracks formed within that zone. Increased loading caused the microcracks to grow from the interlayer to the interface, which led to a complete bond separation after interface cracks emanating from adjacent microcracks linked. In contrast, for the ductile adhesive the crack always grew from the tip. Strain gradients tended to develop there when the bond thickness was large.The adhesive shear strain was determined from fine lines scratched on the specimen edge. For both adhesives, the average crack tip shear strain at crack propagation rapidly decreased with increasing t. This effect was attributed to the changing sensitivity of the bond to the presence of flaws; thicker bonds can accommodate larger microcracks or microvoids which cause greater stress concentration. For a given bond thickness, the critical crack tip shear strain agreed well with the ultimate shear strain of the unflawed adhesive previously determined using the napkin ring shear test [12]. This suggests that the ultimate shear strain is a key material property controlling crack growth. The critical distortional strain energy/unit area of the unflawed adhesive W _s was determined from the area under the stress-strain curve in the napkin ring test. Good agreement between W _s and the adhesive mode II fracture energy was found for all joints tested except for relatively thick bonds. For the particular case of an elastic-perfectly plastic adhesive, the agreement above implies % MathType!MTEF!2!1!+-% feaafiart1ev1aaatCvAUfeBSjuyZL2yd9gzLbvyNv2CaerbuLwBLn% hiov2DGi1BTfMBaeXatLxBI9gBaerbd9wDYLwzYbItLDharqqtubsr% 4rNCHbGeaGak0dh9WrFfpC0xh9vqqj-hEeeu0xXdbba9frFj0-OqFf% ea0dXdd9vqaq-JfrVkFHe9pgea0dXdar-Jb9hs0dXdbPYxe9vr0-vr% 0-vqpWqaaeaabaGaciaacaqabeaadaqaaqaaaOqaaGqaciaa-Deada% WgaaWcbaacbaGaa4xsaiaa+LeacaGFdbaabeaakiabg2da9iaa-Dfa% daWgaaWcbaGaa83CaaqabaGccqGHHjIUcaWF0bGaeqiXdq3aaSbaaS% qaaiaa-LhaaeqaaOGaeq4SdC2aaSbaaSqaaiaa-zgaaeqaaaaa!463A!\[G_{IIC} = W_s \equiv t\tau _y \gamma _f \].     

Constraint comparisons for common fracture specimens: C(T)s and SE(B)s

New testing standards (e.g., ASTM E1921) remain under continuing development to measure the fracture toughness of ferritic steels over the ductile-to-brittle transition. The procedures assume that relatively small, deep-notch test specimens maintain near small-scale yielding conditions at fracture, which simplifies greatly the interpretation of measured values. However, 3-D finite element analyses suggest that the geometry and small size of common fracture specimens leads frequently to constraint loss, e.g., the decay of small-scale yielding conditions, at only moderate levels of deformation. The Weibull stress micromechanical model, or “local approach,” is employed here to quantify these constraint effects. Previous research along these same lines quantifies constraint loss in common fracture specimens relative to strict plane-strain, small-scale yielding conditions with a zero T-stress. Here we present a more practical approach for application within experimental testing programs by comparing directly the two most commonly tested fracture specimens, the single-edge notched bend, SE(B), and the compact tension, C(T), specimens. Developers of testing standards may thus choose a “reference” specimen then correct values measured with other specimens to the adopted reference configuration.     

Investigation of microstructure and flexural behavior of steel-fiber reinforced concrete

This paper presents microstructure and flexural behavior of steel-fiber reinforced concrete produced with different steel fibers volume fraction and aspect ratio. Prismatic concrete specimens of 100 × 100 × 350 mm were prepared with and without steel fiber. Two different steel fiber types (both is hooked-end) were used by ratio of 0% (control), 0.2, 0.4, 0.6 and 0.8% by volume. Specimens were de-molded after 24 h and cured in water until 7, 28, 56, 180 and 360 days. On the prisms, flexural strength has been defined for every age. The crack widths have also been measured after maximum bearing loads. Microstructure of SFRC was studied by scanning electron microscopy and optical microscopy for 180 aged specimens. The results showed that the polarized microcopy images may be used for observing the bond characteristic of SFRC as alternatively to SEM. A good bond was observed between steel fiber and concrete matrix interface zone by using polarizing microscopy, too. Flexural strength of SFRC increased with the concrete age and fiber volume fraction. Besides, the first crack development significantly decreased by increasing of fiber volume fraction in the all concrete ages.     

Composite-to-metal tubular lap joints: strength and fatigue resistance

The axial strength and fatigue resistance of thick-walled, adhesively bonded E-glass composite-to-aluminum tubular lap joints have been measured for tensile and compressive loadings. The joint specimen bonds a 63 mm OD aluminium tube within each end of a 300 mm long, 6 mm thick E-glass/epoxy tube. Untapered, 12.5 mm thick aluminium adherends were used in all but four of the joint specimens. The aluminum adherends in the remaining four specimens were tapered to a thickness of 1 mm at the inner bond end (the bond end where the aluminum adherend terminates). For all loadings, joint failure initiates at the inner bond end as a crack grows in the adhesive adjacent to the interface. Test results for a tension-tension fatigue loading indicate that fatigue can severely degrade joint performance. Interestingly, measured tensile strength and fatigue resistance for joints with untapered adherends is substantially greater than compressive strength and fatigue resistance.The joint specimen has been analyzed in two different ways: one approach models the adhesive as an uncracked, elastic-perfectly plastic material, while the other approach uses a linear elastic fracture mechanics methodology. Results for the uncracked, elastic-plastic adhesive model indicate that observed bond failure occurs in the region of highest calculated stresses, extensive bond yielding occurs at load levels well below that required to fail the joint, and a tensile peel stress is generated by a compressive joint loading when the aluminum adherends are untapered. This latter result is consistent with the observed joint tensile-compressive strength differential. Results of the linear elastic fracture mechanics analysis of a joint with untapered aluminum adherends are also consistent with the observed differential strength effect since a mode I crack loading is predicted for a compressive joint loading. Calculations and a limited number of tests suggest that it may be possible to selectively control the differential strength effect by tapering the aluminum adherends. The effect of adherend material and thickness on fracture mechanics parameters is also investigated. The paper concludes by examining the applicability of linear elastic fracture mechanics to the joints tested.     

Cyclic loading and fracture mechanics of Ductal<Superscript>®</Superscript> concrete

Reactive Powder Concrete (RPC) is a special type of ultra high strength, superplasticized, silica fume concrete, often fibre-reinforced, with improved homogeneity because the traditional coarse and fine aggregate are replaced by fine sand with particle sizes in the range of 100–400 μm [4–16 thousandths of an inch]. RPC properties are attractive because compressive strengths up to 800 MPa [116 ksi] have been recorded, but more typically in excess of 200 MPa [29 ksi]. Flexural strengths up to 141 MPa [20.4 ksi] and fracture energy of 40 kJ/m²[kJ/in.²] have been reported—the latter achieved when steel or stainless steel fibres were included in the mix (Baché (1998) Proceedings of the 2nd international conference on superplasticizers in concrete, Ottawa, pp 35–41; Coppola et al. L’Industria Ital Cemento 707:112–125 (1996); Blais and Couture PCI J 44(5):60–71 (1999); Richard and Cheyrezy (1994) Proceedings of V. Mohan Malhotra symposium on concrete technology: past, present, and future (SP 144). American Concrete Institute, Detroit, pp 507–518; Richard and Cheyrezy Cement Concrete Res 25(7):1501–1511 (1995)). Ductal^®, a commercial RPC, has a compressive strength of approximately 150 MPa [22 ksi] with metallic or organic fibres. All tests described here were performed on 40 × 40 × 160 mm [1.6 × 1.6 × 6.3 in.] (Width (b) × Depth (d) × length (L)) prisms with Poly Vinyl Alcohol (PVA) fibres. Ductal^® is a family of RPC and micro-defect-free concretes containing micro silica, silica fume, cement, Quartz sand, superplasticizer, and PVA fibres. Mechanical and fracture parameters were investigated using four point bending. Low and high cyclic fatigue tests were conducted in three stages, starting from low to high strain cycles. Cracks generated by cyclic fatigue tests were monitored periodically in order to evaluate the rate of crack propagation. Cracks were also investigated using a high magnification microscope. Three pairs of specimens were tested, notched and un-notched to evaluate fracture parameters. Four point bending was used again because determination of the J-Integral (J _IC ) requires the application of pure bending over a portion of the beam. Load was applied at the third points over a span (S) of 120 mm [4.7 in.], providing a span to depth ratio (S/d) of 3.0. Specimens were notched using a 1 mm [0.04 in.] thick diamond saw. The crack tip generated was circular and the crack length (s) was approximately 10 mm [0.4 in.]. Tests on the notched specimens included measurement of the crack mouth opening displacement (CMOD). Closed-loop testing was developed using a feed back signal from the (CMOD) clip gauge attached to the notched specimens and from strain gauges attached to the un-notched specimens. The weight (w) of each specimen was obtained prior to testing. Fracture parameters were calculated from the load–deflection curves obtained from the notched and un-notched specimens.     

Evaluation of Si3N4 joints: bond strength and microstructure

Joining of pressurelessly sintered silicon nitride ceramics was carried out using adhesive slurries in the system Y-Si-Al-O-N in a nitriding atmosphere. The effects of bonding parameters, such as joining temperature (1450–1650°C), applied pressure (0– MPa) and holding time (10–60 min), on the bond strength of joint were evaluated. A typical microstructure of the joint bonded with the optimum adhesive was investigated. The three point bend testing of joined samples with 3 × 4 × 36 mm³ in dimension was employed to study the bond strength of joints. The results show that an optimum joining process was achieved by holding at 1600°C for 30 min under an external pressure of 5 MPa and the maximum bond strength was 550 MPa, compared to 700 MPa of unbonded Si₃N₄ ceramic, using the adhesive having the Si₃N₄/(Y₂O₃ + SiO₂ + Al₂O₃) ratio of 0.39. The good bond strength is attributed to the similarity in microstructure and chemical composition between joint zone and ceramic substrate. The fracture modes were classified into two types according to the values of bond strength. This revised version was published online in September 2006 with corrections to the Cover Date.     

Measurement of bitumen–tyre adhesion temperatures at realistic loading rates

A small-scale apparatus was constructed to measure the ‘adhesion temperature’, at which bitumen ‘pick-up’ onto tyre rubber (and subsequent tracking) occurs. Loading frequencies equivalent to traffic speeds of over 100 km hr^?1 and realistic tyre footprint pressures were used. The adhesion temperature increased with loading frequency, but all of the bitumens and polymer-modified bitumens studied had adhesion temperatures (i.e. the temperature at which the bitumen failed cohesively) at or below 60 °C, a temperature easily reached in the field. The results confirm the findings of an earlier slow-speed study (at 1.6 km hr^?1) and indicate that the adhesion temperature under realistic loading conditions is governed by the properties of the bitumen, i.e. the bitumen yield stress is lower than that of the adhesive bond formed as the tyre traverses the bitumen.     

Experimental and numerical investigation on ductile-brittle fracture transition in a magnesium alloy

Tensile test on smooth and circumferentially notched specimens, systematic observation of fracture surfaces and large deformation finite element analysis were conducted to understand the deformation and failure behavior of a magnesium alloy (AM60). The plastic deformation is considered to be dominated by twining mediated slip. The tensile properties were not sensitive to the strain rates applied (3.3 × 10⁻⁴∼0.1). Corresponding to the same loading level, higher stress triaxiality but lower plastic strain was observed in the specimens with a smaller notch profile radius. Deformation and failure of the magnesium alloy were sensitive to the constraint level and ductile-brittle fracture transition occurred with decreasing the notch profile radius.     

Adhesion of a blood platelet to injured tissue

A numerical study of platelet adhesion to injured endothelial wall during blood flow is conducted using the boundary-element method for Stokes flow. An idealised model is presented where the platelet is treated as an elliptical particle carried over a plane wall in simple shear flow. When the platelet is sufficiently close to the wall, adhesive bonds are established tethering the platelet via receptors distributed around its perimeter to ligands sited at specified locations on an injured section of the wall. A generalised boundary-integral equation of the second kind is formulated to determine the translational and angular velocities of the platelet and the force acting on the platelet due to adhesive bonds. Numerical simulations are performed for a small number of bonds behaving as simple springs, and the force required to capture and immobilise an elliptical particle is estimated. Further simulations conducted using an adhesive bond dynamics model show that bond formation operating at realistic biophysical parameter values can lead to platelet capture and arrest.     

Crack path selection in adhesively bonded joints: the roles of external loads and speciment geometry

This paper investigates the roles of external loads and specimen geometry on crack path selection in adhesively bonded joints. First, the effect of mixed mode fracture on crack path selection is studied. Using epoxy as an adhesive and aluminum as the adherends, double cantilever beam (DCB) specimens with various T-stress levels are prepared and tested under mixed mode fracture loading. Post-failure analyses on the failure surfaces using X-ray photoelectron spectroscopy (XPS) suggest that the failure tends to be more interfacial as the mode II fracture component in the loading increases. This fracture mode dependence of the locus of failure demonstrates that the locus of failure is closely related to the direction of crack propagation in adhesive bonds. Through analyzing the crack trajectories in failed specimens, the effect of mixed mode fracture on the directional stability of cracks is also investigated. The results indicate that the direction of the crack propagation is mostly stabilized when more than 3% of mode II fracture component is present at the crack tip regardless of the T-stress levels in the specimens for the material system studied. Second, using a high-speed camera to monitor the fracture sequence in both quasi-static and low-speed impact tests, the effect of debond rate on the locus of failure and directional stability of cracks is investigated. Post-failure analyses including XPS, Auger electron spectroscopic depth profile, and scanning electron microscopy indicate that as the crack propagation rate increases, the failure tends to be more cohesive and the cracks tend to be directionally unstable. Last, as indicated by the finite element analyses results, the T-stresses, and therefore the directional stability of cracks in adhesive bonds, are closely related to the thickness of the adhesive layer and also the thickness of adherend. This specimen geometry dependence of crack path selection is studied analytically and is verified experimentally.     

Micromechanics of shear deformations in cracked bonded joints

Experiments and analytical analysis were carried out to elucidate the process of crack propagation in adhesively bonded joints loaded in mode II. The adhesive used was a toughened epoxy resin, with the bond thickness varying from a few micrometers to 0.6 mm. The development of a plastic deformation zone at the crack tip was monitored in real-time using a high-magnification video camera. Within the plastic zone the adhesive shear strain, determined from scratch marks applied to the specimen edge, was uniform across the bond except for several bond thicknesses long region just ahead of the crack tip where, depending on bond thickness, noticeable strain gradients may develop. The experimental results suggest that the critical shear strain at the crack tip is a viable fracture criterion. A simplified analysis for the cracked bond which is based on the technical theory of beams/plates and which considers nonlinear adhesive behavior was developed. The model prediction for the increase in the plastic deformation zone with load and the distribution of shear strain within the zone agreed well with the experimental results. An expression for the energy dissipated by the advancing crack was derived which accounted for the nonlinearity in the load vs. deflection curve observed in the fracture experiments and allowed G _IIC to be calculated from easily measurable test parameters.     

Determination of Fracture Toughness of Bone Cement by Nano-Indentation Test

The nano-indentation test was used to measure fracture toughness of the bone cement. The cement sample was prepared using two different mixing methods i.e., hand mixing and vacuum mixing. For this purpose, some cubic specimens, each of the size 10×10×5?mm³ were produced and then the nano-indentation test was performed on both the hand-mixed and the vacuum-mixed specimens by nano-indenter setup and atomic force microscopy observation. The fracture toughness values obtained from the hand-mixed and vacuum-mixed cements were compared. The results indicate that the vacuum-mixed cement has significantly higher fracture toughness compared with the hand-mixed ones. Since the nano-indentation test method needs less sample material, decreases costs and obtains reliable results, it can be considered as a suitable technique for determination of the mechanical properties of bone cements instead of the macroscale test methods.     

Experimental deformation analysis of an adhesively bonded multi-material joint for marine applications

The strength and deformation of full-scale adhesively bonded multi-material joints is studied in this paper. Four joints with a thick layer of methyl methacrylate adhesive (MMA) have been manufactured in shipyard conditions. In two specimens, cracks have been introduced at steel–adhesive and composite–adhesive interfaces. One cracked and one un-cracked specimen were subjected to quasi-static tensile testing; the two remaining specimens were stepwise loaded/unloaded with increasing load until failure. The strain in the adhesive layers was measured with digital image correlation (DIC). This showed a predominant shear deformation and dissimilar shear strain patterns for different bond lines. Fibre Bragg (FBG) sensors were used to monitor strains at steel and composite constituents and to detect the onset and evolution of damage in the un-cracked specimen. Strains measured by FBG sensors correspond well with DIC results at nearby regions. All specimens failed by delamination of the composite panel near the composite–adhesive interface.     

Shear induced toughening in bonded joints: experiments and analysis

Bonded joint specimens were fabricated from composite adherends and either an epoxy or a urethane adhesive. In mixed-mode fracture experiments, the epoxy bonded specimens generally failed by subinterfacial fracture in the composite, while specimens bonded with urethane failed very close to the adhesive/substrate interface. For the epoxy bonded specimens, fracture toughness did not change significantly with mode-mix, but for urethane bonded joints, fracture toughness increased with increasing shear load. Finite element analysis, which modeled specimens bonded with the two adhesives, showed similar trends. The different toughening behaviors for the two bonded joints can be attributed to dissipation of energy through inelastic deformation, which was insignificant in the epoxy-bonded joints but substantial when the urethane was used as the bonding agent.     

Contact behavior of idealized granules bonded in two different interparticle distances: An experimental investigation

This paper presents an experimental investigation on contact behavior of idealized granules bonded in two different interparticle distances, which can be used in discrete element modelling of natural sands featured with interparticle cementation. Firstly, by using the designed specimen preparation devices, two aluminum rods are glued together by adhesive material in two different pre-defined modes, namely thin bond mode and thick bond mode representing different bond thickness between particles. Then, by employing the novel auxiliary loading devices, the mechanical behavior of contact between the bonded rods is obtained while different kinds of forces (i.e., normal force, shear force and moment) are applied in different ways. The experimental results show that both the tension strength and ductility increase with the increasing of bond thickness. However, the force–displacement relationship in compression is characterized with strain hardening in the thin bond mode but strain softening in the thick bond mode. In addition, the peak shear strength and peak rolling resistance increase with the increasing of normal force in the thin bond mode, while they increase with the normal force at first, and then decrease in the thick bond mode. Moreover, the strength envelope is an elliptical paraboloid in the thin bond mode but a teardrop in the thick bond mode in the shear force-normal force-moment space.