Papers by Keyword: Hybrid Joints

Abstract: In multi-material-design, e.g. in the automotive industry, mechanical joining processes like self-pierce riveting are well established, because of their amount of advantages. However, adhesive bonding with one-component structural adhesives is increasingly being used. The combination of the specific advantages of both joining techniques in the form of hybrid joints leads to synergies of quality and reliability, such as high corrosion resistance and better damping properties. A critical issue is the generation of global deformations of the different parts of the mechanical joints. These global deformations of the sheet metal between two or more mechanical connectors (e.g. rivets) are caused by the formation of adhesive bags during the riveting process, before the adhesive curing takes place. This research focuses on the time-dependent formation process of these bags. The aim is to achieve a reduction of global deformations based on detailed knowledge of the adhesive flow during the manufacturing of the joint by means of experiments and simulations. For this purpose experimental techniques and measurement methods for deformations over time are presented for different setups of hybrid joint types of self-piercing rivets in combination with adhesive bonding. The challenge is to track rapid and small surface deformations very accurately in the ongoing mechanical joining process. High-speed optical measurement technology like Point-Tracking and surface scanning are used to track the resulting deformations experimentally. Numerical investigations, which include the interaction of the solid matter influenced in the mechanical joining process and the fluid adhesive, are presented. On the basis a fully coupled fluid-structure interaction simulation of a single hybrid joint, a surrogate model for a multi-point hybrid joint is developed. The comparison of experimental data with simulations allows deriving the pressure distribution and flow velocities inside the adhesive layer. The influence of various parameters can be interpreted based on the physics of the interacting system, ultimately resulting in optimization helpful to the automotive industry.

Abstract: In the present paper, results of experimental tests carried out on hybrid (bonded/bolted) and adhesive composite single-lap joints are showed. The laminate adherends were made by unidirectional carbon fiber/epoxy with symmetric stacking sequence. In particular, the tests were carried out to evaluate strength and failure mode of the different joints. These joints were subjected to quasi-static tensile displacement and tests were conducted using a universal testing machine. The maximum tension load that the specimen can bear is determined and the failure process is correlated to the lay-up of the composite and joint type.

Abstract: Hybrid joining of structural parts (e.g. [3-1) is relatively new approach to create more safe and reliable connection of the critical part of engineering structures. In this paper we consider hybrid joint consisting of 2 aluminum stripes and an angle bar (e.g. [7]) joined by 2 simple techniques: hot spot welding (HSW) and adhesive bonding (AB). The samples were subjected to fatigue tests in order to find fatigue response at different level of load amplitude. New method of plastic deformation measurement during fatigue was proposed with application of Digital Image Correlation (DIC) method. Numerical analysis of the hybrid joint fatigue response was proposed in the paper taking into account both: gradual degradation of the bonding layer and plastic damage in the aluminium strips due to cyclic loading.

Abstract: A review of some of the various fatigue models introduced over the years for both metallic materials, in particular aluminium alloys followed by fatigue and durability concerns associated with composite materials. The move towards light weight and high stiffness structures that have good fatigue durability and corrosion resistance has led to the rapid move from metal structures to composite structures. With this brings the added concern of certifying new components as the damage mechanisms and failure modes in metals differ significantly than composite materials such as carbon fiber reinforced polymers (CFRP). The certification philosophy for composites must meet the same structural integrity, safety and durability requirements as that of metals. Hence this is where the challenge now lies. Substantial work has been conducted in the reparability of composite structures through bonding using various adherend thicknesses and joint types and has been shown to have higher durability than mechanically fastened repairs for thin adherends however these are currently unacceptable repair methods as they cannot be certified. Repairs are designed on the basis that the repair efficiency can be predicted and should be designed conservatively with respect to the various failure modes and include the surrounding structure.

Abstract: The use of composite materials as a replacement for commonly used metals such as aluminium and steel are increasing in the engineering industry, particularly in the aerospace sector. The move towards light weight and high stiffness structures that have good fatigue durability and corrosion resistance has led to the rapid move from metal to composites. This change allows for further flexibility in design and fabrication of various components and joints. There are three main categories of joints used in composite materials – mechanically fastened joints, adhesively bonded joints and the combination of the two called hybrid joints. In order to adequately understand the effectiveness of these joints, substantial testing and validation is required, particularly in the use of hybrid joints for real life applications. Static testing, load distribution and parametric studies of hybrid joints have been investigated by various researchers; however further work is still required in understanding the durability and fatigue of hybrid joints and ensuring that both the adhesive and mechanical fasteners can work together effectively in producing an optimum joint. Mechanical fastening alone in composite laminates is not a preferred joining method as they create high stress concentrations around the fastener holes. Adhesive bonding although has numerous benefits it is difficult to detect the bond defect particularly in cases where weak bonds can occur during applications and it is sensitive towards the environmental conditions. Thus hybrid joints are seen arguably as being more effective in joining composite components together and offer greater residual strength. Hence the performance, strength and long-term durability of these joints need to be further investigated and be applied to practical situations whilst assisting in repair certification.

Abstract: The interface fracture process of most layered or bonded structures is commonly under the control of mixed mode cracking where the interface shear and normal fracture components exist simultaneously when the hybrid joints are bonded with different adherend materials. In this work, a simple and novel method is proposed to realize and characterize the pure mode I interface fracture for the hybrid joints with dissimilar substrates. The theoretical and experimental results indicate that the present method may be considered as a standard test method for the characterization of hybrid joints with dissimilar materials.

Abstract: Aluminum (Al) and Magnesium (Mg) alloys are nowadays widely employed in order to produce lightweight automotive and aeronautical components and to gain fuel saving and reduced emissions. However, the joining of Al and Mg alloys poses well known technical problems and the application of conventional joining techniques, e.g. welding, may be ineffective. On the other hand, adhesive bonding may be considered as a candidate replacement of the traditional techniques and for this reason it has been recently proposed as an alternative technology for Al/Mg joints. In particular, it has been demonstrated that adhesive bonding, in conjunction with state-of-the-art surface treatments, can provide Al/Mg joint with enhanced strength. However, in order to evaluate the potential of adhesive bonding to outperform the conventional joining techniques a systematic comparative analysis is needed. Therefore, the aim of this work is to supplement the existing studies on Al/Mg bonding providing a comparative analysis between Al/Mg joints prepared using gas metal arc (MIG) welding, riveting and adhesive bonding. Probably, the use of adhesive bonding as complementary joining process will be the industrial answer to the hybrid joints performance needs.