Search Results (107)

Driven by regulatory and environmental demands, composite structures must combine high structural performance, recyclability, and resource efficiency. Here, an investigation on the structural adhesive bonding of glass-fibre-reinforced thermoplastic Elium© composite laminates is undertaken. Substrates are manufactured using vacuum infusion. Evaluation is performed on the following three commercial two-component adhesives cured at RT: an epoxy (EP), a polyurethane (PU), and an acrylate system (AC). Based on Dynamic Mechanical Analysis, the glass transition temperatures of the EP, PU, and AC adhesives are 56.5, 102.9, and 111.9 °C, respectively. The AC adhesive exhibits the highest shear strength and displacement at failure, reflecting a superior load-bearing capacity. Fractographic analysis further supports these findings: AC joints show a mixed substrate/cohesive failure mode, while EP samples fail exclusively by adhesion failure and PU samples predominantly by a mixture of special cohesion, adhesion and substrate failure. Regarding processing, the EP samples show the highest pot life, followed by PU and then AC. Nonetheless, the pot life of the AC adhesive does not limit its range of application.. The results highlight the advantages of adhesive bonding of Elium© in enabling lightweight and more circular composites. RT-cured adhesives eliminate the need for drilling and energy-intensive thermal curing, allowing design flexibility and reductions in CO₂ footprint within composite production. Full article

Installing shear walls in a load-bearing system is one of the most rational, economical, and effective strengthening methods for improving a building system that is vulnerable to seismic effects. One of the most significant points to consider in a reinforced concrete building strengthened with a shear wall is the sufficiency and reliability of anchorage elements in the shear wall–foundation joints, where significant bending moments will occur due to the impact of lateral loads. This study investigated the behaviour of different foundation anchorage methods, including internal anchorage (anchor bars) and external anchorage (steel angle and carbon-fibre-reinforced polymer (CFRP)) applied at the wall–foundation interface in retrofitted weak reinforced concrete frames, which were multi-span, multi-storey, lacking sufficient seismic detailing, and strengthened using wing-type shear walls, under quasi-static lateral loading. It was also aimed to determine the most effective anchorage method for improving the structural performance. A total of six undamaged, but seismically deficient, two-storey, two-span reinforced concrete frames were strengthened with added shear walls that incorporated different anchorage details at the shear wall–foundation joint. According to the test results, the addition of wing-shaped reinforced concrete rehabilitative walls significantly increased the lateral load-carrying capacity, lateral stiffness, and energy dissipation capacity of reinforced concrete frames with poor seismic behaviour. It was observed that additional strengthening was not required in the edge columns of frames with rehabilitative walls of a sufficient length, but that additional measures were required in the foundation anchors at the base of the strengthening wall due to the further increase in the rehabilitative wall capacity. Consequently, the most suitable shear wall foundation anchorage arrangement was achieved with test specimens where one internal anchor bar was used for each vertical shear reinforcement, independently of the shear wall length, and the development length was the highest. Full article

Short fibre-reinforced adhesives (SFRAs) are increasingly used in wind turbine blades to enhance stiffness and fatigue resistance, yet their heterogeneous microstructure poses significant challenges for predictive modelling. This study presents a fully automated digital workflow that integrates micro-computed tomography (µCT), image processing, and finite element modelling (FEM) to investigate the mechanical response of SFRAs. Our aim is also to establish a computational foundation for data-driven modelling and future AI surrogates of adhesive joints in wind turbine blades. High-resolution µCT scans were denoised and segmented using a hybrid non-local means and Gaussian filtering pipeline combined with Otsu thresholding and convex hull separation, enabling robust fibre identification and orientation analysis. Two complementary modelling strategies were employed: (i) 2D slice-based FEM models to rapidly assess microstructural effects on stress localisation and (ii) 3D voxel-based FEM models to capture the full anisotropic fibre network. Linear elastic simulations were conducted under inhomogeneous uniaxial extension and torsional loading, revealing interfacial stress hotspots at fibre tips and narrow ligaments. Fibre clustering and alignment strongly influenced stress partitioning between fibres and the matrix, while isotropic regions exhibited diffuse, matrix-dominated load transfer. The results demonstrate that image-based FEM provides a powerful route for structure–property modelling of SFRAs and establish a scalable foundation for digital twin development, reliability assessment, and integration with physics-informed surrogate modelling frameworks. Full article

Inconel 625 is widely employed in high-temperature and corrosive environments, where the integrity of welded joints critically influences component performance. This study systematically investigates how laser beam welding (LBW) heat input governs cooling behaviour, microstructure evolution, elemental segregation, and the mechanical performance of Inconel 625 weld joints aiming to become sustainable joints. A single-spot monochromatic non-contact type infrared pyrometer is used to monitor the thermal cycles of the molten weld pool and the cooling rate and melt pool lifetime were determined based on the thermal cycle data. The impact of cooling rate and melt pool lifetime on weld geometry, microstructure, micro-segregation, and mechanical properties were thoroughly investigated. The findings revealed that the fibre laser welding produced sound, defect-free joints across all experimental heat-input conditions and the weld quality was fairly dictated by cooling rate during solidification. Reducing heat input (by using faster laser scan speeds) increased the cooling rate (1.45 × 10³ to 3.65 × 10³ °C/s), resulting in a shortened melt-pool lifetime and altered weld bead geometry from hourglass to truncated-cone profiles. Eventually, the fusion-zone microstructure transitioned from coarse cellular/columnar dendrites at high heat inputs to refined dendrites at low heat inputs. The EDS analysis revealed pronounced Nb and Mo segregation in slowly cooled welds and Laves phase formation due to insufficient time for solute redistribution and γ-Ni matrixes were consistent noted with XRD-observed peaks. The presence of the brittle Laves phase adversely affects the microhardness and tensile strength of the weld joints. Mechanical testing confirmed that decreasing heat input (in faster laser scan speeds) enhanced micro-hardness and tensile strength due to grain refinement and solute entrapment in the γ matrix. The highest joint strength (989.3 ± 10.4 MPa) and elongation (40.3 ± 1.8%) approached those of the work material, and these findings establish processing parameter–structure–property relationships for the LBW of Inconel 625. The co-relation in the present manuscript can be used in the future for process monitoring and for controlling the mechanical properties of laser welding and may provide a practical guidance for optimizing weld quality in advanced industrial applications. Full article

FRP composite bridges have been in operation since the mid-1990s, allowing for the evaluation of their long-term behaviour. Many of the early FRP bridges in the USA and Western Europe were equipped with monitoring systems to assess their structural integrity after years of use. In Poland, the first all-FRP composite bridge was also equipped with a modern structural health monitoring (SHM) system based on distributed fibre optic sensing (DFOS) to enable long-term performance monitoring. Over nearly a decade of use, the bridge’s strain, stiffness, and dynamic properties have been evaluated three times through static and dynamic load tests. Research findings indicate that the bridge has maintained satisfactory structural integrity and durability over an eight-year operational period. However, the quality of the adhesive joints between the girders and the deck panels was found to be inadequate, resulting in a slight decrease in the bridge’s performance, specifically in stiffness and dynamic characteristics. Fortunately, these negative changes did not compromise the bridge’s safety or serviceability, as stipulated by the design requirements. An effective repair was completed, restoring the bridge to its full operational efficiency. Full article

This research addresses the critical gap in accurately modelling pultruded fibre-reinforced polymer (FRP) beam-to-column joints, where previous studies largely ignored progressive damage mechanisms. A novel finite element framework is developed in ABAQUS, integrating Hashin’s failure criterion with fracture energy-based damage evolution to simulate delamination and brittle failure in FRP cleats. The model is rigorously validated against full-scale experimental data, achieving close agreement in moment–rotation response, initial stiffness (within 5%), and ultimate moment capacity (variation < 10%). Quantitative results confirm that delamination at the fillet radius governs failure, while qualitative analysis reveals the sensitivity of stiffness to cleat geometry and bolt characteristics. A parametric study demonstrates that increasing cleat thickness and bolt diameter enhances stiffness up to 15%, whereas bolt–hole clearance introduces slip without significantly affecting strength. The validated FEM reduces reliance on costly physical testing and provides a robust tool for optimising FRP joint design, supporting the future development of design guidelines for pultruded FRP structures. Full article

Research into technological processes, such as welding, provides the basis for optimising the strength and quality of PVC joints, which are becoming increasingly important in the context of sustainable construction. The study analysed the influence of welding parameters on the quality and strength of the welds of PVC window profiles reinforced with glass fibre composite. The variable parameters were welding time (21–25 s) and composite milling depth (up to 1 mm). The constant parameters were a welding temperature of 264 °C and a head feed rate of 0.25 mm/s. The results showed that the most favourable results were achieved with a composite milling depth of 1 mm and a melting time of 22 s, which provided the highest average failure load values and met the strength requirements. Additionally, the white welds confirmed that the welding process had been carried out correctly, with no depolymerisation or material degradation occurring. In contrast, milling depths of less than 1 mm or no milling depth at all resulted in problems with dimensional tolerance. In addition, overloading of the welding machine during the welding process was observed for composite milling depths of less than 1 mm and a melting time of 22 s. The results of the study highlight the need for further analysis of the influence of other process parameters, including welding temperature. Full article

The use of pultruded-fibre-reinforced polymer (PFRP) composite profiles in structural applications is rapidly increasing, due to their high strength-to-weight ratio, corrosion resistance, and durability. Bolted joints between PFRP play a critical role, as localized high stresses in a material that typically exhibits brittle behaviour—especially in tension and shear—can lead to sudden failure. This study aims to investigate the mechanical performance of such bolted connections (in terms of stiffness, strength, displacement capacities and failure modes), contributing to the development of reliable yet optimized design criteria for structural applications. In particular, numerical analyses of single-bolted connections in PFRP profiles are presented in the paper. To emphasize the general validity of the model and demonstrate its applicability across different configurations, the simulations were validated against experimental results from three separate test campaigns, which varied in both material (three different PFRP composites) and geometry (profile thickness, bolt diameter, and hole–end distance). Finite element models using continuum shell elements in ABAQUS, based on the Hashin failure criteria, successfully captured typical failure modes, including shear-out and pin-bearing. Two analysis approaches—implicit and explicit solvers—were also compared and discussed. Sensitivity analyses were carried out to enhance the model’s accuracy and its computational efficiency. The validated model was then extended to simulate different configurations, investigating the role of the main parameters influencing the connections. Full article

This paper describes the development of a new hybrid composite for the metal joints of aluminium and glass fibre composite adherents. The aluminium adherend is manufactured using friction stir-formed studs that are inserted into the composite adherend in the through-thickness direction during the composite manufacturing process, where the dry fibres are displaced to accommodate the studs before the resin infusion process. The materials used were AA6082-T6 aluminium and plain-woven E-glass fabric reinforced epoxy, with primary applications in naval vessels. This joining approach offers a cost-effective solution that does not require complicated onsite welding. The joint design was developed based on a simulation test program with finite element analysis, followed by experimental characterisation and validation. The design solution was analysed in terms of the force displacement response, sequence of load transfer, and characterisation of the joint failure modes. Full article

This paper deals with an important issue, which is the influence of failure caused by the quality of matrix post-curing on the strength of complex and difficult materials of the “new generation” such as fibre composites, particularly with a polymer matrix. In recent years, significant advances in the field of adhesive materials chemistry have led to the constant development of bonding technology. The effectiveness of bonding depends, to a large extent, on the suitable selection of the adhesive and the use of appropriate surface treatment technology. It is difficult to imagine virtually any modern industry without adhesive joints, be it the aircraft, aerospace or automotive industries, which simultaneously highlights the great importance of adhesives and adhesive materials for the present-day economy. In modern technology, it is extremely important to obtain the right combination of modern construction materials. The statistical analysis of the components showed the complexity of the layered composite structure. The proposed model of the weakest micro-volume developed in this study indirectly reflects the experimentally based curing variables that affect the stresses of the components in the composite (laminate) structure. The strength of fibrous composite structures based on the Markov chain theory considers technological aspects during hardening. The model proposed in the paper was validated on the basis of examples from the literature and experimental data obtained in the research project. The numerical results are in good agreement with the literature database and measurement data. The presented model could be a novel method, which allows better insight into the curing process of epoxy resins. Full article

This study investigates the mechanical and fatigue behaviour of friction stir composite joints fabricated from an aluminum alloy (AA6082-T6) and a glass fibre-reinforced polymer (Noryl^® GFN2) under different service temperature conditions. The joints were tested under both quasi-static and cyclic loading at three different temperatures (23, 75, and 130 °C). Fracture surfaces were analyzed, and the probabilistic S–N curves were derived using Weibull distribution. Results indicated that increasing the service temperature caused a non-linear decrease in both the quasi-static and fatigue strength of the joints. Compared to room temperature, joints tested at 75 °C and 130 °C showed a 10% and 50% reduction in average tensile strength, respectively. The highest fatigue strength occurred at 23 °C, while the lowest was at 130 °C, in line with the quasi-static results. Fatigue stress-life plots displayed a semi-logarithmic nature, with lives ranging from 10² to 10⁵ cycles for stress amplitudes between 7.7 and 22.2 MPa at 23 °C, 7.2 to 19.8 MPa at 75 °C, and 6.2 to 13.5 MPa at 130 °C. The joints’ failure occurred in the polymeric base material close to joints’ interface, highlighting the critical role of the polymer in limiting joints’ performance, as confirmed by thermal and scanning electron microscopy analyses. Full article

Forming hybrid structures into complex shapes is key to address lightweighting of automotive parts. Recently, an innovative joining technique between aluminium and Carbon Fibre-Reinforced Polymer (CFRP) based on mechanical interlocking through sheet punching has been developed. However, scaling up the solution requires the assessment of challenges, such as multi-material forming and joint integrity, after forming operations. Therefore, this work proves the feasibility of forming aluminium–CFRP prepreg panels into complex omega-shaped profiles following a conventional cold-stamping process. Forming without defects was possible even in specimens featuring mechanical joints generated through punching. The effect of the CFRP position (in the inner or the outer side of the formed profile), the number of mechanical joints, the addition of a Glass Fibre-Reinforced Polymer (GFRP) intermediate layer to prevent galvanic corrosion and adequate lubrication on necking, cracking, springback behaviour and the final geometry after curing were studied. Compression tests were performed to assess the mechanical response of the hybrid profile, and the results showed that the addition of CFRP in the aluminium omega profile changed the buckling behaviour from global bending to axial folding, increasing the maximum compression load. Additionally, the presence of mechanical interlocking joints further improved the mechanical performance and led to a more controlled failure due to buckling localization in the geometric discontinuity. Full article

The IDEA project, developed in the frame of MOST—National Centre for Sustainable Mobility—addressed the growing need for reliable bonded joints in fibre-reinforced polymer composite structures used in transportation. Purely bonded joints are preferred for their lightweight and cost-efficient properties, but contamination and defect detection issues often make them unreliable. To solve this, the project developed innovative surface treatments, a methodology for the safe, optimized design of bonded joints, and structural health monitoring solutions, viable for real-time assessment. These advancements aim to increase the reliability and safety of bonded connections, helping industries adopt lighter, purely bonded joints over heavier, hybrid bonded/bolted options. Full article

To achieve the sustainability goals set for the European aviation sector, hydrogen-powered solutions are currently being investigated. Storage solutions are of particular interest, with liquid hydrogen tanks posing numerous challenges with regard to the structural integrity of materials at cryogenic temperatures, as well as safety issues because of the high flammability of hydrogen. In this context and in the scope of the Horizon 2020 Clean Aviation Joint Undertaking (CAJU) project H2ELIOS, the gas permeability behavior of prepreg tape carbon fibre reinforced polymer (CFRP) material was studied. Investigations were performed after thermal shock to 20 K (liquid hydrogen immersion) as well as after a uniaxial stress application at 77 K to identify the shift from Fickian behavior after diverse aging conditions. Helium gas permeation was tested at room temperature (RT), and its representativeness to hydrogen permeation in a range of temperatures was considered in the study. The material’s permeation behavior was compared to ideal Fickian diffusion as a means of identifying related permeation barrier function degradation. Finally, it was possible to identify Fickian, near-Fickian, and non-Fickian behaviors and correlate them with the material’s preconditioning. Full article

Background/Objectives: Anterior disc displacement without reduction (ADDwoR) is a temporomandibular joint (TMJ) disorder characterized by progressive dysfunction and potential complications. Persistent displacement leads to abnormal mechanical stress, predisposing the TMJ disc to structural degeneration, including perforation. This case report aimed to examine the histological and immunofluorescence characteristics of perforated disc tissue to elucidate the mechanisms contributing to its pathology. Methods: A 50-year-old patient with bilateral ADDwoR and disc perforation underwent functional arthroplasty. Tissue samples from the perforated disc were histologically analyzed using hematoxylin–eosin and Azan Mallory staining. Immunofluorescence was performed to assess the expression of collagen type I, fibrillin-1, matrix metalloproteinases (MMPs)-3 and -9, and cluster of differentiation 68 (CD68). Results: Histological analysis revealed disorganized collagen fibres and fibro-chondrocyte cell predominance in the perilesional zone, accompanied by vascular proliferation. Adjacent tissue to perforation exhibited normal fibrous organization. Immunofluorescence showed reduced collagen type I and fibrillin-1 patterns in the perilesional area, indicating an alteration in the fibrillar component of the extracellular matrix (ECM). Increased expression of MMP-3 and MMP-9, as well as elevated numbers of CD68-positive macrophages, suggested active ECM degradation and inflammation localized to the perforation site. Conclusions: This case report underscores the critical role of biomechanical stress and inflammation in disc perforation. Decreased ECM integrity, driven by altered collagen and fibrillin composition, as well as heightened MMP activity, compromises the disc’s capacity to absorb and distribute mechanical loads. These findings advance our understanding of TMJ pathophysiology, emphasizing the need for therapeutic approaches that target both biomechanical stabilization and inflammation. Full article