Testing adhesives and adhesively bonded joints

UNIVERZITET U ZENICI
Mašinski fakultet
PART III:
Testing adhesives and adhesively bonded joints
Aleksandar Karač
MFZE, room 1111
Tel: 449 120, ext. 140
Email: akarac@mf.unze.ba TESTING PRODUCT CHARACTERISTICS
TESTING PRODUCT CHARACTERISTICS
About adhesives and adhesively bonded joints*
Adhesive – a polymeric material which, when applied to the surfaces of materials,

can join them together and resist separation.
Structural adhesive – an adhesive that, once it is hardened, has a modulus and

strength sufficiently high so that load-bearing joints may be constructed (epoxy).
i) single-part adhesives, which require heat-curing at elevated temperatures, and

ii) two-part adhesives, that can cure at room temperature.
* Georgiu I., The Fracture of Adhesively-Bonded Aluminium Joints for Automotive Structures PhD, 2003
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Rubber- toughened epoxies
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Adhesives in automotive industry
Energy consumed during the life cycle of a vehicle
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Adhesives in automotive industry
BMW ‘X5’ with a steel monocoque body structure Audi ‘A2’ with an all aluminium-alloy space-frame body structure
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Main advantages
• Adhesive bonding offers the possibility to join dissimilar materials; e.g. metals, plastics, fibre-
composites, wood, etc. Dissimilar metals can be joined in this way, since the adhesive prevents
intimate contact, which could otherwise lead to galvanic corrosion.
• Adhesives have the ability to join thin sheet-material efficiently.
• A good joint design will be energy-absorbing, and tend to have good noise and vibration
damping properties.
• The adhesive may essentially have a dual purpose since, as well as providing mechanical
strength, the adhesive may seal the joint against moisture and debris ingress.
• The smooth appearance of the joints produced using adhesives results in lower stress
concentrations at the joint edges. Thus, the load is more evenly distributed and stress
concentrations are minimised. As a result, a more effective dynamic-fatigue resistance of the
component or structure can be obtained.
• Adhesive bonding is often a convenient and cost-effective technique. Process automation by
robot minimises the necessity of any human interaction and, with the increased development of
flexible manufacturing systems, adhesive bonding may be an integrated part of the assembly line.
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Main limitations
• The surface pre-treatment of the substrates to be joined have a major effect on the strength
of the joint, in particular under severe environmental conditions.
• Adhesive bonding has a limited service temperature range compared with the other
fastening techniques.
• The strength and toughness of adhesives are typically relatively low compared to metals,
and therefore their use is limited to only joining thin sheet metals.
• Commercial techniques for non-destructive testing of adhesively-bonded joints are
relatively limited compared to those used with other fastening methods.
• Adhesive joints are inherently weak in peel; and vehicle designs need to take account of
this, particularly with regard to crashworthiness.
• There is a lack of information and knowledge concerning the potential failure of bonded
joints under impact conditions.
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Adhesives in use
Volvo vehicle joined using adhesives. A Volvo Vehicle manufacture using an epoxy adhesive. Here,
vehicle is joined by adhesives using a proportional vehicle - robotically delivered single-part heat-curable
adhesive dispenser epoxy adhesive
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Adhesively bonded joints
(a) (b)
(a) (b) (c)
Simple Simple
Beveled Beveled
(c) (d)
Single taper Single

(d) (e)
Double taper Double
Increased thickness Beveled
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Testing of adhesives and adhesively bonded joints
Impact Wedge-Peel (IWP) Test

Uniaxial tension
Mechanical properties Uniaxial compression
High-rate tension
T-Peel Test
Small-scale peel tests
Fracture behaviour of joints
IWP-Impact behaviour
e.g. IWP and T-Peel tests
T-Peel-Large strains
Deep notched tensile

Failure properties
TDCB – FV simulation
of adhesive/substrate
TDCB Test Charpy test
Axial compression
Thin-walled structures Quasi-Static
e.g. double-hat beams
Double Hat Beam (DHB) High loading rates
Modelling of T-Peel
Model the impact behaviour
Modelling of IWP
of bonded structures
Modelling of DHB
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Uniaxial tensile tests
PC
Load-Cell Instron Series IX
Software
INSTRON 4466
Output from Load-Cell

Specimen
Cross-Head
Output from Extensometer
Extensometer
Self-Adjusting Grips
Low-rate tests high-rate tests
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Uniaxial tensile tests
60 90
80
50
70
40 60
Stress [MPa]
Stress [MPa]
50
30
0.0000027 /s 40
0.0000025 /s
0.000025 /s 0.000024 /s
20 30
0.00036/s 0.00028 /s
0.0036/s 0.0032 /s
0.034/s 20
10 0.030 /s
0.21 /s
10 0.18 /s
2.20 /s
2.10 /s
0 0
0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.00 0.01 0.02 0.03 0.04 0.05 0.06
Strain Strain
HD 1493 HD 4600
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Uniaxial compression
100
90
80
70
60
Stress [MPa]
High strength steel Polished surfaces 50
compression plates Test specimen
40
30
Specimen height - 12 mm
20 Specimen height - 10 mm
10
0
0.0 0.1 0.2 0.3 0.4
Strain
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Fracture properties
y y y
I II IǿI
0 0 0
x x x
z z z
Mode I Mode ǿI Mode ǿII
Mode I – tensile opening mode
Mode II – in-plane shear
Mode III – anti-plane shear
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Charpy tests
(a)
80 mm
10 mm
Machine ram
Load-cell 2-12 mm
2.5 mm
Striker Notch (b) 80 mm
a Substrate Adhesive layer

W 0.4 mm
10 mm
l
(a) 2.5 mm Notch 12 mm
Clamping bolts Spacer Aluminium Adhesive

substrate
(b) Specimen supports

Application of a weight to prevent
Bondline adjustment bolts vertical misalignment of the substrates
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Charpy tests
800
'XD1493'
(b) ‘XD4600’ ‘XD1493’
700 'XD4600'
(b)
600
500
Load [N]
400
300
Damage zone RCP Damage zone RCP
200
100 (c) (c) Sharpened Machined notch

(a) notch
0
0.000 0.001 0.002 0.003 0.004
Time [ms]
‘XD4600’ ‘XD1493’
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Tapered Double-Cantilever Beam (TDCB) Tests

Machine ram
Amplifier Load-Cell
Rubber washers
for damping contact
INSTRON 1185
Specimen
Ram motion
Analog Output from
Fylde
Load-Cell
Lost motion
TDCB specimen
Extension Rod device
TDCB Specimen
Loading shackle
Loading pin
X-Y Plotter
Camera
Piezo-electric
Universal joints load-cell
Support
Static load-cell
Cross-Head
Fixed base
Low-rate tests high-rate tests
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mb
P Loading holes
hs(a)
Inserted film = 80 mm
P 10 mm
Film length = 90 mm Sharp crack Substrate arms Adhesive
Crack length a
Total specimen length = 310 mm
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(a) (b)
3500 300
'XD1493' 'XD1493'
'XD4600' 270 'XD4600'
3000
240
2500
210
Cross-head load [N]
Crack length [mm]

2000 180
150
1500
120
1000 90
60
500
30 ~ 20.5 m/s Crack speed ~ 16.5 m/s
0 0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Time [ms] Time [ms]
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[ ]
(a) (b)
2000 200
Average initiation value Fci Image processing 1
Crack propagation region

1800 180 Image processing 2
1600 160
Crack arrest region

1400 Fca 140
Crack length [mm]

Average arrest value
1200 120
Load [N]
1000 100
Crack initiation
800 80
600 60
Pre-crack
400 40
200 20 1-2 5-6 9-10 Frames 15-17
0 0
0 2 4 6 8 10 12 14 16 18 20 8 9 10 11 12 13 14 15 16 17 18 19 20
Time [ms] Time [ms]
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(a) Traction free boundary condition

Cohesive zone model
Mixed boundary condition
Fixed boundary condition
Hybrid contact/CZ model boundary condition
Adhesive layer Back side 10226 Finite Volumes
51.5 mm
15.9 mm
Front side
Front side: Traction free

90 mm Back side: Symmetry plane
310 mm
Numerical simulation
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p
50000000
50000000
Time: 10 min Time: 70 min
Displacements magnified by 40000000
40000000
a factor of 5 for clarity 30000000
30000000
20000000 y
20000000
y
10000000 x
10000000 x
0
0
-10000000
-10000000
Damage zone in front
-20000000
-20000000
z of the crack tip
z
50000000 Pre-crack location 50000000
Time: 40 min Time: 100 min

40000000
40000000
30000000
30000000
y 20000000 y
20000000
10000000 x 10000000 x
0
0
Compressive region
-10000000
-10000000
-20000000
-20000000
z z
Crack tip
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(a) 2500 (b) 300
2000 240
Cross-head load [N]
Crack length [mm]

1500 180
1000 120
Experimental
Experimental
σmax = 20 MPa
σmax = 20 MPa σmax = 35 MPa
σmax = 35 MPa 60 σmax = 50 MPa
500
σmax = 50 MPa
σmax = 60 MPa
σmax = 65 MPa
σmax = 80 MPa
σmax = 80 MPa ~ 2.0 mm/min
0 0
0 20 40 60 80 100 120 0 20 40 60 80 100 120
Time [min] Time [min]
CZM calibration
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3200 150 2000
2800 1800
125
Cohesive strength, σm ax [MPa]

Fracture toughness, GIC [J/m2]
1600
2400
1400
100
Cross-head load [N]

2000
1200
1600 75 1000
1200 800
50
600
800
400
25
400 Adhesive fracture energy, GIc Experiment results
Cohesive strength, σmax 200 FV numerical prediction
0 0 0
0 5 10 15 20 25 30 35 40 45 0 1 2 3 4 5 6 7 8 9 10 11
Crack velocity [m/s] Displacement [mm]
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Peel tests
P
P P
B Substrates
(a) single-arm peel test Peeling arm
(b) T-peel test Adhesive
B h
θ Adhesive
Substrate
h
(a) (b)
(a) Specimen grip
Impact peel test Adhesive Substrates

(a) symmetric (b) Bolt
(b) asymmetric
Specimen
support
Applied
displacement
Wedge Spacer
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T-peel tests
12
Mean Value
Test 1
10 Test 2
100 mm
Substrate 1 Test 3
Adhesive layer 8
P/B [N/mm]
thickness ~ 0.25 mm
Inserted film Average Force

4
180 mm
200 mm
A.A.5754: 1 mm thick
2
Substrate 2 Test speed: 50 mm/min
Mean force: 8.5±0.3 N/mm
20 mm
0
0 40 80 120 160 200 240 280 320 360 400
Displacement [mm]
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T-peel tests
(b) 1 2 3 4
(a) 10
1 2 3 4 5 6 7 8 9 10 11 12 13 14
9
8 1
7
5 6 7 8
Force [N/mm]
3
9 10 11 12
2
Peeling force N/mm
27
1 N Frame Number
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Time [s]
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Impact-wedge-peel tests
Clamping Guillotine
Shelf-lock clamp
Specimen
Jig Substrates A3 Al. Sheet
Tapering Drilling
Locating pins
Forming-Wedge Spacer
Movable pieces for clamping

Fixed pieces
Specimen preparation
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Machine ram
Rubber washers
for damping contact
1800 50
Force [N]
Ram motion
Displacement [mm] Lost motion device
1500
40
1200
Displacement [mm]
30
Force [N]
900 Specimen grips
20
600 Wedge
Strain gauges
10
300 Specimen
Camera
0 0
0 2 4 6 8 10 12 14 17
Time [ms] Piezo-electric
load-cell
Static
load-cell
Fixed base
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(a)
(b)
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Substrate
Wedge 16800 Finite Volumes

Contact boundary
condition
1-2 mm
3.2 mm
30 mm 20 mm
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Box-beam components
75 mm
(a) Adhesive layer
50 mm
60 thickness ~ 0.4 mm
60
Adhesive h
m
580
m
(b) (c)
0
52
–
R
0
15
22
R = 3h
Note: All dimensions in mm
10 - 25 mm
Al. Rivets
∅ 6 mm 110 - 125 mm
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Box-beam components
Regular progressive collapse
Front view
Front view
Front view
Side view
Side view
Side view
(a) TH beam, riveted at 25 mm pitch - Type I. (b) Rivet bonded TH beam joint using the
`XD4600’ adhesive and a pair of end
rivets - Type IV.
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Box-beam components
1 2 3 4
110
Rivet-bonded DH beam (type IV ) - failure pattern FP1
100 Adhesively-bonded DH beam (type V ) -failure pattern FP2
90
80
70
Load [kN]
60
50 Adhesive fracture leads
5 6 7 to a premature failure of
40 the component.
30
20
10
0
0 10 20 30 40 50
Displacement [mm]
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Deep-notched tensile tests 30

50% LBA ratio
200x 30% LBA ratio
10% LBA ratio
20
LBA ratio (%)
Traction (MPa)
P
Damage evolution -globa
10
50
0
0 2 4 6 8 10
Separation (mm)
30
10
P Start Stop
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Deep-notched tensile tests
(a) (b)
PTFE layer
Notch
Bulk area Adhesive
Notch
Ligament area
80-120 mm
10-20 mm
40 mm
10-20 mm
40 mm
Aluminium
(substrate)
Adhesive DNT specimen; (b) Adhesive/substrate DNT specimen
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Deep-notched tensile tests
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Deep-notched tensile tests - current
PTFE layer
Adhesive
1 mm
63 mm
Aluminium
(substrate)
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UNIVERZITET U ZENICI
Mašinski fakultet
PART IV:
Testing wood and wood products, crash tests ...
Aleksandar Karač
MFZE, room 1111
Tel: 449 120, ext. 140
Email: akarac@mf.unze.ba TESTING PRODUCT CHARACTERISTICS

Testing adhesives and adhesively bonded joints

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Testing adhesives and adhesively bonded joints

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