Quality assurance concepts for adhesive bonding of composite aircraft structures – characterisation of adherent surfaces by extended NDT

In order to ensure the performance of adhesively joined load-critical composite structures, suitable technologies are needed to steadily monitor adherent surfaces prior to bonding and to detect adhesion properties of bonded components. A novel class of non-destructive testing (NDT) techniques, classified as extended non-destructive testing (ENDT), is required to ascertain selected physicochemical properties which are important for the performance of adhesive bonds in place of detecting material defects like conventional NDT methods do. The European FP7 project, ‘ENCOMB – Extended non-destructive testing of composite bonds’ aims in the identification, development, adaptation and validation of ENDT methods for characterisation of adherent surfaces and adhesive bond quality. Here, recent NDT techniques such as optically stimulated electron emission (OSEE) and aerosol wetting test (AWT) as well as laser-induced breakdown spectroscopy (LIBS) were advanced and applied in field, and without contacting carbon fibre-reinforced polymer (CFRP) surfaces for detecting different contamination layers such as release agent, moisture or hydraulic oil as well as thermal degradation of CFRP adherent surfaces before performing an adhesive bonding process. Sensitivity and accuracy of these techniques allow distinguishing surface states which are suitable for bonding of CFRP adherents from surface states which are unfavourable for bonding. ENDT using OSEE, AWT and LIBS facilitated the detection of layers of release agent as thin as one nanometre and thin layers resulting from hydraulic oil. OSEE investigations of adherent surfaces before adhesive bonding allowed the indication of all surface states of potential CFRP adherents, which according to previous studies, were related to application scenarios reducing the joint strength of resulting adhesive joints by 20–70%.     

胶接接头无损检测研究进展

介绍了胶接接头无损检测技术近年来的发展情况，对超声波、声、应力波等无损检测技术的发展作了概要的阐述，同时对胶接接头的强度检测进行了分析，认为检测中所选用的强度相关参数，应充分体现胶接接头对应力的响应，这样才可能实现胶接强度的定量检测。     

A review of finite element analysis of adhesively bonded joints

The need to design lightweight structures and the increased use of lightweight materials in industrial fields, have led to wide use of adhesive bonding. Recent work relating to finite element analysis of adhesively bonded joints is reviewed in this paper, in terms of static loading analysis, environmental behaviors, fatigue loading analysis and dynamic characteristics of the adhesively bonded joints. It is concluded that the finite element analysis of adhesively bonded joints will help future applications of adhesive bonding by allowing system parameters to be selected to give as large a process window as possible for successful joint manufacture. This will allow many different designs to be simulated in order to perform a selection of different designs before testing, which would currently take too long to perform or be prohibitively expensive in practice.     

Determination of traction-separation laws on an acrylic adhesive under shear and tensile loading

Structural acrylic adhesives are of special interest because those adhesives are cured at room temperature and can be bonded to oily substrates. To use those adhesives widely for structural bonding, it is necessary to clarify the methodology for predicting strengths of bonding structures with those adhesives. Recently, cohesive zone models (CZMs) have been receiving intensive attentions for simulation of fracture strengths of adhesive joints, especially when bonded with ductile adhesives. The traction-separation laws under mode I and mode II loadings require to estimate fracture toughness of adhesively bonded joints. In this paper, the traction-separation laws of an acrylic adhesive in mode I and mode II were directly obtained from experiments using Arcan type adhesively bonded specimens. The traction-separation laws were determined by simultaneously recording the J-integral and the opening displacements in the directions normal and tangential to the adhesive layer, respectively.     

In situ cure monitoring of adhesively bonded joints by dielectrometry

Since the reliability of adhesively bonded joints is much dependent on the curing status of thermosetting adhesives, the in situ cure monitoring during the cure of adhesive joints could improve the quality of adhesively bonded joints as it enables one to control the cure parameters. In this work, a dielectric method which measures the dissipation factor of the adhesive during the cure of joints and converts it into the degree of cure of the adhesive was devised. Steel adherends were used for the adhesively bonded joints because the steel adherends worked as the electrodes for the measurement of dissipation factor without additional electrodes. The relation between the dissipation factor and the degree of cure of adhesive was investigated, which could eliminate the temperature effect on the dissipation factor that is largely affected by the degree of cure and temperature of adhesive. Comparing the results obtained by the method developed with those by DSC (differential scanning calorimetry), it was found that the dissipation factor showed a trend similar to the cure rate of the adhesive.     

Failure behavior of adhesively bonded joints with a rubber modified epoxy adhesive under tensile-shear combined cyclic loading

Rubber-modified epoxy adhesives are used widely as structural adhesive owing to their properties of high fracture toughness. In many cases, these adhesively bonded joints are exposed to cyclic loading. Generally, the rubber modification decreases the static and fatigue strength of bulk adhesive without flaw. Hence, it is necessary to investigate the effect of rubber-modification on the fatigue strength of adhesively bonded joints, where industrial adhesively bonded joints usually have combined stress condition of normal and shear stresses in the adhesive layer. Therefore, it is necessary to investigate the effect of rubber-modification on the fatigue strength under combined cyclic stress conditions. Adhesively bonded butt and scarf joints provide considerably uniform normal and shear stresses in the adhesive layer except in the vicinity of the free end, where normal to shear stress ratio of these joints can cover the stress combination ratio in the adhesive layers of most adhesively bonded joints in industrial applications.

In this study, to investigate the effect of rubber modification on fatigue strength with various combined stress conditions in the adhesive layers, fatigue tests were conducted for adhesively bonded butt and scarf joints bonded with rubber modified and unmodified epoxy adhesives, wherein damage evolution in the adhesive layer was evaluated by monitoring strain the adhesive layer and the stress triaxiality parameter was used for evaluating combined stress conditions in the adhesive layer. The main experimental results are as follows: S–N characteristics of these joints showed that the maximum principal stress at the endurance limit indicated nearly constant values independent of combined stress conditions, furthermore the maximum principal stress at the endurance limit for the unmodified adhesive were nearly equal to that for the rubber modified adhesive. From the damage evolution behavior, it was observed that the initiation of the damage evolution shifted to early stage of the fatigue life with decreasing stress triaxiality in the adhesive layer, and the rubber modification accelerated the damage evolution under low stress triaxiality conditions in the adhesive layer.     

Mechanical behaviour of adhesively bonded polyethylene tapping tees

The mechanical properties of adhesively bonded MDPE joints were studied. The lap-shear joints were prepared using PE80 polyethylene gas pipe and four adhesive types; two acrylic and two epoxy resins. The key mechanical properties of lap shear strength and impact resistance were investigated as a function of adhesive type and surface preparation technique. Mechanical abrasion of the PE80 surface increased the strength of the bonds from 40 to 460% for the four adhesives, with the best performing acrylic adhesive having a lap-shear strength of 1.76 MPa and impact strength of 2.5 kJ/m². When used to bond PE80 tapping tees to PE80 gas pipe, the acrylic adhesive produced a gas tight seal at both the standard test pressure of 0.4 MPa and at an increased pressure of 0.8 MPa, and outperformed the PE80 tapping tee during shear testing and withstood a maximum of 10 cycles of 175 J during impact testing. These results highlight the potential of adhesive bonding as a method of joining PE80 tapping tees to PE80 gas pipe.     

Effects of Different Curvature Patches on the Strength of Double-Strap Adhesive Joints

In general, the damage in adhesively bonded joints initiates from and propagates through the ends of the overlap area due to high stress concentration in that area. The reduction of these stress concentrations results in an increase in the strength of the joints. For this reason, the rounding of the overlap region before bonding and then applying compression during the bonding process will exert compressive residual stresses on the adhesive layer in the overlap end regions. It is known that the residual stresses formed in this process increase the failure strength of the joint and hence delay the initiation of the damage.

In this study, the effects of overlap length (L = 50,75, and 100 mm), patch thickness (h = 1.6, 3.2, and 5 mm) and patch materials (AA2024 aluminum alloy, AISI 304 steel, AISI 1040 steel) on bond strength were experimentally investigated for adhesively bonded double-strap joint (DSJ) and curvature double-strap joint (CDSJ) subjected totensile loading. The experimental study showed that the overlap length, patch thickness and patch materials have considerable influence on the failure strength and displacement capacity of the joints.     

Finite element analysis of torsional free vibration of adhesively bonded single-lap joints

Adhesively bonding is a high-speed fastening technique which is suitable for joining advanced lightweight sheet materials that are dissimilar, coated and hard to weld. In this paper, the free torsional vibration characteristics of adhesively bonded single-lap joints are investigated in detail using finite element method. The effectiveness of finite element analysis technique used in the study is validated by experimental tests. The focus of the analysis is to reveal the influence on the torsional natural frequencies and mode shapes of these joints caused by variations in the material properties of adhesives. It is shown that the torsional natural frequencies and the torsional natural frequency ratios of the adhesively bonded single-lap joints increases significantly as the Young′s modulus of the adhesives increase, but only slight changes are encountered for variations of Poisson's ratio. The mode shapes analysis show that the adhesive stiffness has a significant effect on the torsional mode shapes. When the adhesive is relatively soft, the torsional mode shapes at the lap joint are slightly distorted. But when the adhesive is relatively very stiff, the torsional mode shapes at the lap joint are fairly smooth and there is a relatively higher local stiffening effect. The consequence of this is that higher stresses will be developed in the stiffer adhesive than in the softer adhesive.     

Stress Analysis of Adhesively Bonded Electroprimed Steel Lap Shear Joints

Structural applications for adhesive bonding have been increasing in recent years due to improvements in the types of adhesives available and in improved knowledge of bonding procedures. Consequently, there exists a demand for precise numerical modeling of adhesive joint behavior, particularly along bondline interfaces where low surface energy adhesives contact high surface energy metallic oxides. The purpose of the present study is to determine the effect of electrodeposited organic paint primer (ELPO) on the stress and strain distributions within an adhesively bonded single-lap-shear joint. Initial experimental studies have shown that bonding to ELPO-primed steel adherends has enhanced strength and durability characteristics compared to conventional bonds to unprimed steel surfaces. Recent studies based on finite element analysis of varied single-lap-shear joint moduli and thicknesses, and subsequent testing of joints with two different adhesive moduli, have indicated the mechanisms involved in this phenomenon. The presence of the ELPO-primer reduced peak peel and shear stresses and allowed for more uniform stress distribution throughout the joint.     

Stress Analysis of Adhesively Bonded Electroprimed Steel Lap Shear Joints

Structural applications for adhesive bonding have been increasing in recent years due to improvements in the types of adhesives available and in improved knowledge of bonding procedures. Consequently, there exists a demand for precise numerical modeling of adhesive joint behavior, particularly along bondline interfaces where low surface energy adhesives contact high surface energy metallic oxides. The purpose of the present study is to determine the effect of electrodeposited organic paint primer (ELPO) on the stress and strain distributions within an adhesively bonded single-lap-shear joint. Initial experimental studies have shown that bonding to ELPO-primed steel adherends has enhanced strength and durability characteristics compared to conventional bonds to unprimed steel surfaces. Recent studies based on finite element analysis of varied single-lap-shear joint moduli and thicknesses, and subsequent testing of joints with two different adhesive moduli, have indicated the mechanisms involved in this phenomenon. The presence of the ELPO-primer reduced peak peel and shear stresses and allowed for more uniform stress distribution throughout the joint.     

Piezoelectric monitoring of the reliability of adhesive joints

Since the reliability of adhesively bonded joints for composite structures is dependent on many parameters such as the shape and dimensions of joints, type of applied load, and environment, so an accurate estimation of the fatigue life of adhesively bonded joints is seldom possible, which necessitates an in-situ reliability monitoring of the joints during the operation of structures. In this study, a self-sensor method for adhesively bonded joints was devised, in which the adhesive used works as a piezoelectric material to send changing signals depending on the integrity of the joint. In order to validate the method, the piezoelectric properties of the adhesive were measured during the fatigue test. Electrically conducting adherends were used as electrodes without embedded sensors, and the adhesively bonded joint was modeled as the equivalent parallel circuit composed of electric charge and capacitance. From the investigation, it was found that the electric charge increased gradually as cracks initiated and propagated in the adhesive layer, and had its maximum value when the adhesively bonded joint failed. So it is feasible to monitor the integrity of the joint during its lifetime. Finally, a relationship between the piezoelectric property of the adhesive and crack propagation was obtained from the experimental results.     

Degradation of Mode-I Fracture Toughness of CFRP Bonded Joints Due to Release Agent and Moisture Pre-Bond Contamination

An experimental investigation of the effects of pre-bond contamination on Mode-I fracture toughness of carbon fiber reinforced plastic (CFRP) bonded joints is presented in this paper. Two pre-bond contamination scenarios were considered; namely, the silicon-based release agent and moisture. The two contamination scenarios were realized in one of the composite substrates prior to bonding. The common characteristic of the two contamination scenarios is that they lead in the formation of defects in the form of weak bonds that cannot be detected by conventional non-destructive testing techniques. The contamination effects on Mode-I fracture toughness of the bonded joints were investigated by conducting mechanical tests on double-cantilever beam specimens and comparing the results with relative measurements taken from reference specimens. Prior to mechanical testing, the bonding quality of the specimens was tested using ultrasonic C-scan inspection. Both the release agent and moisture are found to significantly degrade the Mode-I fracture toughness of the joints. For the release agent, the effect was more significant for silicon concentrations over 5 at%; a complete lack of adhesion was observed for silicon concentrations over 7 at%. At low values of relative humidity, there was a small increase in Mode-I critical energy release rate while at larger values there is a decrease which reaches 26% for the higher relative humidity percentage. The results from the Non-Destructive Testing (NDT) tests verify the inability of conventional NDT to detect the defects resulting at the interface between the contaminated adherend's surface and the adhesive for both contamination scenarios.     

Development of a Fatigue Failure Model for the Adhesively Bonded Tubular Single Lap Joint under Dynamic Torsional Loading

The adhesively bonded tubular single lap joint shows nonlinear torque transmission capability and deformation characteristics under static torsional loading because of nonlinear properties of the adhesive. However, the dynamic or fatigue torque transmission capability can be calculated with linear, analysis because the stress-strain relation under torsional fatigue loading is linear, due to the small dynamic transmission capability compared with the static torque transmission capability.

In this paper, a failure model for the adhesively bonded tubular single lap joint under torsional fatigue loading was developed with respect to the adhesive thickness, which is the critical factor for the static torque transmission capability. Also, a design method for the adhesively bonded tubular single lap joint under torsional fatigue loading was proposed.     

Modeling of single-lap composite adhesive joints under mechanical and thermal loads

Two-dimensional (plane-stress and plane-strain) theoretical models are presented for stress analysis of adhesively bonded single-lap composite joints subjected to either thermal or mechanical loading or a combination thereof. The joints consist of similar/dissimilar orthotropic or isotropic adherends and an isotropic adhesive interlayer. The governing differential equation of the problem is obtained using a variational method which minimizes the complementary strain energy in the bonded assembly. In this formulation, through-thickness variation of shear and peel stresses in the interlayer is considered. Both shear and normal traction-free boundary conditions are exactly satisfied. Peel and shear stresses obtained from plane-strain analytical models considering a homogeneous adhesive interlayer are in close agreement with those of the finite element predictions. A systematic parametric study is also conducted to identify an ideal set of geometric and material parameters for the optimal design of single-lap composite joints.     

An innovative approach to fatigue disbond propagation in adhesive joints

An innovative approach to characterize the resistance of adhesively bonded joints to fatigue disbond propagation (FDP) is presented. A constitutive equation, known as the modified crack layer (MCL) model, is employed to extract parameters characteristic of the adhesive joint's resistance to FDP. These parameters are γ', the specific energy of damage, which reflects the fatigue disbond resistance of the adhesive joint and the dissipative characteristic of the joints, β'. Stress-controlled tension-tension fatigue experiments were conducted on lap joints fabricated from aircraft grade aluminum 2024-T3 and 3M structural adhesive. The disbond length was measured periodically along the edges of the bonded area at the four corners and the corresponding number of cycles was recorded. This is in order to calculate the disbond growth rate. The hysteresis loop was also recorded for each measurement from which both the energy release rate, J*, and the change in work, W_i, were determined. It was found that the proposed model describes the behavior of the adhesively bonded joints over the entire range of the energy release rate. Thus, the proposed model can provide a basis upon which the relationships between the microstructure and/or the processing conditions and the resistance of adhesively bonded joints to FDP can be constructed. Such relationships can guide the development of adhesively bonded joints with superior resistance to debonding and should aid in their lifetime assessment.     

Improvement in Strength of Adhesively Bonded Single-Lap Joints Using Reinforcements

In order to enhance the strength of adhesively bonded single-lap joints (SLJs), the adhesively bonded SLJs with reinforcements were proposed. Adhesively bonded SLJs of different substrates and with different reinforcements were investigated experimentally and numerically. Scanning electron microscopy was performed on the fracture surfaces of the joints to analyze the failure mechanism. Shear stresses and peeling stresses of the adhesive layer were calculated with finite element analyses (FEA). Results showed that the deformation of the joints decreased with an increase in stiffness at the end of the overlap region. The strength increase in adhesively bonded SLJs with reinforcements was validated by the results from experimental tests and FEA.     

The Use of a Modified Mixed Mode Bending Test for Characterization of Mixed-mode Fracture Behavior of Adhesively Bonded Metal Joints

This paper summarizes recent mixed-mode I and II fracture experiments on adhesively bonded metal joints using a modified mixed-mode bending (MMB) test fixture and double cantilever beam (DCB)-type specimens. The MMB test had been previously developed and used for mixed-mode I and II delamination testing of composite laminates, but in the present research it is adapted and modified for fracture testing of adhesively bonded joints with metallic adherends. Strain energy release rates were evaluated by the use of improved analytical models. Mixed-mode fracture behavior of AA5754-0 aluminum alloy specimens bonded with a tough one-part epoxy adhesive (Dow Automotive Betamate 4601 ® ) was characterized.     

Tensile Strength of Joints Bonded With a Nano-particle-Reinforced Adhesive

In order to improve the tensile lap shear strength of adhesively bonded joints, nano-particles were dispersed in the adhesive using a 3-roll mill. The dispersion states of nano-particles in the epoxy adhesive were observed with TEM (Transmission Electron Microscopy) with respect to the mixing conditions, and the effect of nano-particles on the mechanical properties of the adhesive was measured with respect to dispersion state and weight content of nano-particles. Also the static tensile load capability of the adhesively bonded double lap joints composed of uni-directional glass/epoxy composite and nano-particle-reinforced epoxy adhesive was investigated to assess the effect of nano-particles on the lap shear strength of the joint. From the experimental and FE analysis results, it was found that the nano-particles in the adhesive improved the mechanical properties of the adhesive. Also the increased failure strain and the reduced CTE (coefficient of thermal expansion) of the nano-particle-reinforced adhesive improved the lap shear strength of adhesively bonded joints.     

Application of the design of experiments procedure to the behaviour of adhesively bonded joints with plastically deformable adherends to enable further understanding of strain rate sensitivity

The study presented in this paper was carried out to investigate further the effects of strain rate on the strength of adhesively bonded single lap shear joints. Tests were carried out on two different configurations of adhesively bonded joints that were designed to exhibit different behaviours. In one configuration both adherends were made from a relatively low strength grade of aluminium such that both would exhibit significant plastic deformation prior to adhesive failure. The other configuration used one adherend that was significantly stronger such that only elastic deformation was exhibited prior to failure of the adhesive. The joint specimens were tested at several different strain rates using a servo-hydraulic test machine and the results analysed using statistical methods. To further understand the results Finite Element models of the joints were created using a Cohesive Zone Model to predict damage development and failure in the adhesive. The Design of Experiments procedure was used to study the effects of material parameters relating to both the adherends and the adhesive in the Finite Element models. The results of the testing suggested that the strength of joints formed from two adherends that exhibited plastic deformation prior to failure did not show statistically significant sensitivity to strain rate. Interpretation of the results of the Finite Element analyses suggested that the adherend yield was the main factor influencing failure load in the adhesive for joints of this type.