Search Results (505)

Carbon fiber-reinforced thermoplastic (CFRTP) composites are now widely used in many fields. Ultrasonic welding (UW) is a key technology for joining these materials. The control mode of UW has a great effect on the quality of the welded joints. However, there is still not enough research comparing the different welding control modes. This paper investigates the effects of the time control, energy control, and displacement control modes on the ultrasonic welding quality of carbon fiber-reinforced polycarbonate (CF/PC). A flat PC film is used as the energy director (ED). The evaluation focuses on the lap-shear strength (LSS), macro- and micro-morphology, fracture surface characteristics and power–displacement curves of the welding process. Furthermore, significant differences are observed in the temperature field evolution and joint failure modes across the different control modes and process parameters. Results indicate that the displacement control mode achieves the highest joint quality and process stability, yielding a maximum LSS of 30.6 MPa. A correlation analysis reveals that the displacement–energy relationship exhibits the strongest coupling, and the Pearson correlation coefficient r is 0.896. Full article

The valorization of agro-industrial byproducts as sources of functional polysaccharides is a promising strategy for developing sustainable materials. In this study, cellulose was extracted and purified from rice husk and apple pomace through sequential alkaline and bleaching treatments. Then it was chemically modified via TEMPO-mediated oxidation to obtain cellulose nanofibers (TOCNFs) with cellulose yields ranging from 23.8 to 32.4% for rice husk and 9.3–13.8% for apple pomace. Owing to its higher recovery and structural regularity, rice husk was selected for surface modification with 3-aminopropyltriethoxysilane (APTES). The resulting TOCNFs exhibited an average width of 8 nm and a carboxyl content of 0.48 mmol g⁻¹. Fourier-transform infrared spectroscopy (FTIR), X-ray diffraction (XRD), and nitrogen determination (1.72 mg g⁻¹) confirmed the presence of aminosilane functionalities. APTES-modified TOCNFs were incorporated as active components to develop hybrid poly(vinyl acetate) (PVA) adhesives synthesized via in situ heterogeneous water-based polymerization. The influence of TOCNF surface chemistry and sodium dodecyl sulfate (SDS) on latex particle size, rheological behavior, and adhesive performance was systematically investigated. Latex particle size increased from 193 nm (PVA-SDS) to 625 nm with TOCNF-APTES and decreased to 247 nm upon SDS addition. Rheological analysis revealed pronounced shear-thinning behavior associated with the formation of percolated nanofibrillar networks, with low-shear viscosity increasing up to 477 Pa·s for TOCNF–APTES and decreasing to 370 Pa·s with SDS. Lap-shear testing (ASTM D905) showed substantial improvements in adhesive strength, reaching up to 250 kPa compared to PVA-SDS. These results demonstrate that surface-modified CNFs act not only as mechanical reinforcements but also as interfacially active components governing polymerization behavior, rheology, and adhesive performance. This exploratory study provides a proof-of-concept for the development of sustainable wood adhesives from agro-industrial byproducts. Full article

The main purpose of this study was to investigate the effects of 10, 20, and 40 wt% micron-sized particles (aluminum nitride, aluminum oxide, silicon nitride, and silicon oxide) on the thermal performance of an epoxy resin used in microelectronic devices. Specimens were produced via a solution mixing technique followed by molding and curing. Although there were slight differences between the particle types used, various thermal analyses revealed that increasing the amount of all particle types significantly improved the thermal performance of the epoxy resin. The property that influences the thermal performance of microelectronic devices the most is thermal conductivity (λ). Heat produced during operation should be released via heat diffusion, which requires a certain level of λ. In this study, the use of a 40 wt% particle content increased the thermal conductivity (λ) by more than 3 times compared to neat epoxy (0.15 W/m·K). Another significant problem during the operation of these devices is the formation of “thermal strain mismatch” due to the different thermal expansion coefficients (α) of the materials used in the device that might lead to a loss of dimensional stability and malfunctioning. In this study, a particle content of 40 wt% decreased the thermal expansion coefficient of epoxy (49 × 10⁻⁶/K) down to 28 × 10⁻⁶/K, a decrease of −43%. Thermal performance also depends on the Glass Transition Temperature (T_g) values. In this study, a particle content of 40 wt% increased the T_g from 51 °C (neat epoxy) to 68 °C, an increase of 17 °C, and increased the Thermal Degradation Temperature (T_d) from 324 °C (neat epoxy) to 356 °C, an increase of 32 °C. Moreover, it was also revealed that there was no decrease in the lap shear adhesion strength of the epoxy resin after incorporation of any of the particle types. Additionally, the particles also increased the mechanical rigidity of the epoxy in terms of Storage Modulus at 25 °C and 50 °C. Full article

The applicability of two different joining processes for producing lap joints from high-strength steel sheets is investigated, reflecting their increasing use in advanced lightweight structures with demanding performance requirements. The work is primarily focused on the joining-by-forming process known as double-flush riveting, evaluated in two variants: one utilizing forged holes and the other employing machined holes. The performance of these two variants is compared with conventional fusion-based resistance spot welding using lap joints fabricated from 2 mm high-strength low-alloy S500MC steel sheets under varying geometric and process conditions, with support from finite element modelling. Results indicate that both double-flush riveting variants produce similar joint cross-sectional geometries, but the machined hole variant simplifies sheet preparation and eliminates the need for a progressive tooling system. Tensile lap-shear and peel test results reveal that double-flush riveted joints with forged holes exhibit superior strength, attributed to strain hardening in the forged regions. Furthermore, for nuggets and rivets of equivalent size, both double-flush riveting variants surpass resistance spot welding in terms of the mechanical strength of the final joints. These results suggest that double-flush riveting represents a promising alternative for assembling high-strength steel sheets in lightweight structural applications. Full article

This research work addresses the mechanical and metallurgical characterisation, as well as the failure features, of two types of lap-fillet autogenous laser-welded joints made of ultra-thin sheets by applying an appropriate welding technology for producing sound welds and flawless joints. Both welded samples, one made only of stainless steel (SS-SS) sheets, and the other made of stainless steel and carbon steel (SS-CS) plates, were subjected to tensile–shear loads that are representative of the in-service conditions. The experimental research was focused on determining, by the digital image correlation (VIC-2D) method, the strain field and the rotation angle of the welded joints that were developed during loading tests of the welded specimens. Comparing to the classical testing method applied to study the joint overall mechanical properties, the novelty of this research consists of local mechanical behaviour assessment of relevant zones from similar and dissimilar welded joints, by using the innovative technique VIC-2D. Based on the analysis of the experimental results, it was found that the maximum rotation angle is 2.5 times higher in the SS-SS similar welded joint, in comparison with the SS-CS dissimilar welded joint. Despite this finding, the SS-CS specimen failed in the CS base material, far from the weld, with the failure phenomenon being preceded by the material yielding and necking. This failure mode is consistent with the detected strength mismatch of the SS-CS joint, with respect to the CS base material. In contrast, the quasi-ductile fracture of the SS-SS welded joint occurred by plastic exhaustion at the boundary between the narrow Heat-Affected Zone (HAZ) of SS and the Fuzion Zone (FZ). These outcomes are consistent with the hardness profile, microstructural heterogeneities found in the lap-fillet welded joints, and the load versus elongation curves that are determined and discussed in this paper. This research provides new insight and original information on the materials’ response to the autogenous laser welding, which will contribute to improving the knowledge on the ultra-thin lap-fillet welded similar and dissimilar steels. Full article

The use of carbon fiber-reinforced plastic (CFRP) components has increased significantly in civilian aviation, necessitating effective maintenance and repair strategies to ensure durability and performance. While prior studies have focused on composite repair methods, such as stepped scarf patch and bolted joint repairs, these were limited to specimen and panel levels without addressing full-scale wing models. This study bridges that gap by evaluating stepped-lap repairs on a full-scale composite wing model under realistic loading conditions and exploring various repair scenarios. To reduce computational cost, two-dimensional shell elements were employed to simulate repairs, with results validated using experimental tensile test data from stepped-lap repaired specimens. Numerical models were developed for single regions and two closely located repair regions. For single-region repairs, adding up to two extra layers enhanced mechanical strength, but three extra layers increased strain, diminishing performance. For two closely located repairs, additional layers improved strength, though less effectively than single-region repairs. Square-shaped repairs exhibited higher strain due to stress concentrations at the corners, while circular repairs showed more uniform stress and strain distribution. These findings emphasize the importance of optimizing repair geometry and layer configurations using numerical simulations to ensure optimal structural performance of CFRP components. Full article

Adhesive bonding has emerged as a promising technology for joining carbon fiber reinforced polymer (CFRP) structures in aircraft, offering advantages over traditional mechanical fastening such as weight reduction and uniform stress distribution. This study evaluates the effectiveness of innovative laser ablation and electrospinning surface treatments compared to the conventional peel-ply method for secondary bonding. Surface features and wetting behavior were characterized using scanning electron microscopy (SEM) and contact angle measurements, while mechanical performance was assessed via single lap shear tests. Results demonstrate that laser ablation (30 W power, 10 m/s speed) achieved the highest bond strength at 20.68 MPa, followed by electrospinning (18.20 MPa) using 10 wt% PA-66 nanofibers. Both advanced techniques significantly outperformed the peel-ply method, which yielded the lowest shear strength of 15.18 MPa. SEM analysis confirmed that laser treatment facilitated direct fiber exposure with minimal damage, while nanofibers provided enhanced physical interlocking. In conclusion, laser ablation proved to be the most effective technique for enhancing interfacial bonding in aerospace-grade CFRP structures, followed by electrospinning, offering a superior alternative to traditional surface preparation. Full article

Diaphragm walls are widely used for deep foundation pit support and permanent underground structures. The joints between adjacent panels are critical weak points, significantly influencing the overall deformation and stress distribution of the structure. To address the insufficient shear and tensile capacity of existing diaphragm wall joints, this study proposes a novel rigid joint incorporating retractable shear studs. The joint features a straightforward and constructible design, primarily comprising retractable shear studs, H-section steel, and shear stud pop-out limit plates. By withdrawing the limit plates inserted into the H-section steel, the retractable shear studs mounted on the web automatically extend along their axis, penetrating into the adjacent reinforcement cage to form an intrusive lap joint. This mechanism effectively enhances the integrity and load-bearing capacity at the joint. To validate its mechanical performance, large-scale specimens featuring this new joint were fabricated and subjected to shear and tensile tests. The experimental results demonstrate that, compared to traditional H-section steel joints, the peak shear and tensile strengths of the proposed joint are increased by approximately 10 times and 16 times, respectively. These findings fully verify the excellent mechanical performance of the novel diaphragm wall joint structure. Full article

In this paper, the bond performance of tensile lap-spliced Glass and Basalt Fiber-Reinforced Polymer bars is investigated in high-strength concrete. Eighteen large-scale GFRP-reinforced concrete beams were fabricated and subjected to four-point loading. Key parameters explored included bar diameter and splice length for both GFRP and BFRP reinforcement. The results indicate that the flexural capacity of GFRP-reinforced beams was comparable to that of BFRP-reinforced beams, though BFRP bars exhibited marginally superior bond and strength with concrete. The bond strength of spliced FRP bars was directly proportional to the splice length. This study also determined that characteristics of development lengths necessitate splice lengths that exceed the bar diameter 40 times to mitigate bond stress. Critical splice lengths, derived from experimental findings, were compared with existing models and code-based equations, specifically, Guide for the Design and Construction of Structural Concrete Reinforced with Fiber-Reinforced Polymer Bars (ACI 440.1R-15) and Canadian standard that provides comprehensive guidelines for incorporating Fiber-Reinforced Polymer reinforcement in concrete structures (CSA S806-12). Both codes were conservative in splice length prediction for GFRP and BFRP bars, with ACI 440.1R-15 showing greater accuracy for BFRP bars with a larger diameter. A modification factor, based on hyperbolic functions, is proposed to enhance the accuracy of ACI 440.1R-15 in predicting splice lengths for various FRP bar diameters. Full article

Biopolymer adhesives are moving toward frontline use in medicine and manufacturing as the limitations in some petrochemical systems, including cytotoxicity, challenges in wet adhesion for specific families of synthetic resins and formaldehyde emissions associated with amino-formaldehyde materials are becoming increasingly difficult to accept. This review integrates mechanisms, material classes and quantitative performance across biopolymer-based adhesives. We focus on architectures that combine permanent covalent anchoring with reversible, energy-dissipating bonds and on how functional group density, crosslink density, microstructure and additives act as design knobs for wet performance, durability and degradation. Across biomedical applications, chitosan, alginate, gelatin and related hydrogels achieve wet lap-shear strengths on the order of tens of kilopascals, cut liver-bleeding times by roughly half, provide strong antibacterial activity and close diabetic wounds by about 92 percent by day 14. Thermoresponsive alginate–gelatin sealants exceed clinically relevant burst pressures and microneedle patches withstand more than 120 mmHg while sealing arteries in under a minute. In industrial settings, dialdehyde-based starch resins deliver 0.83 to 1.05 MPa dry shear and maintain strength after water immersion while meeting stringent emission classes, and silane-modified nanocellulose in urea–formaldehyde markedly reduces free formaldehyde without sacrificing the internal bond. We conclude by identifying priorities for standardized wet testing, and lifetime matching of strength and degradation that can support large-scale clinical and industrial translation. Full article

Background: Durable bonding to zirconia remains difficult because its chemically inert surface resists acid etching. Additive manufacturing (AM) enables controlled surface morphology, which may enhance micromechanical retention without additional treatments. Methods: Zirconia specimens with three AM-derived surface designs—(1) concave–convex hemispherical patterns, (2) concave hemispherical patterns, and (3) as-printed surfaces—were fabricated using a slurry-based 3D printing system and sintered at 1500 °C. Zirconia specimens fabricated by subtractive manufacturing using CAD/CAM systems, polished with 15 µm diamond lapping film and with or without subsequent alumina sandblasting, served as controls. Surface morphology was analyzed by FE-SEM, and shear bond strength (SBS) was tested after cementation with a resin-based luting agent. Results: SEM revealed regular layered textures and designed hemispherical structures (~300 µm) in AM specimens, along with step-like irregularities (~40 µm) at layer boundaries. The concave–convex AM group showed significantly higher SBS than both sandblasted and polished subtractive-manufactured zirconia (p < 0.05). Vertically printed specimens demonstrated greater bonding strength than those printed parallel to the bonding surface, indicating that build orientation affects resin infiltration and interlocking. Conclusion: AM-derived zirconia surfaces can provide superior and reproducible micromechanical retention compared with conventional treatments. Further optimization of printing parameters and evaluation of long-term durability are needed for clinical application. Full article

Reliable joining of multi-layer aluminum foil current collectors is crucial for enhancing the performance and safety of high-capacity lithium-ion batteries. However, laser welding of such thin-thick aluminum combinations is often hindered by porosity, cracks and unstable weld-pool behavior. In this study, a ring-mode fiber laser combined with sinusoidal oscillation and linearly gradient power modulation was employed to achieve high-quality lap welding between 80 layers of 1060 aluminum foil (1 mm in total thickness) and a 1.5 mm thick aluminum plate. Welding experiments and thermo-mechanical simulations were conducted to investigate the effects of welding speed (15–45 mm/s) and central-power modulation parameters (−2, 0, +2, +4) on weld morphology, defect formation, and mechanical properties. The results indicate that increasing the welding speed can effectively suppress cracks and improve the shear strength from 249.8 N to 403.9 N, but it also leads to an increase in porosity from 5.78% to 12.26% and deterioration of the weld reinforcement. Higher central-power modulation (+2, +4) transformed the weld-pool geometry from an ω shape to U shape, effectively suppressing fusion-line cracks but leading to increased porosity (up to 8.41%) and deteriorated surface morphology. Overall, a low welding speed of 15 mm/s combined with an optimized power modulation strategy achieves effective crack suppression while maintaining controlled porosity, resulting in a welded joint with superior comprehensive performance. This research provides a robust process solution for high-quality laser welding of multi-layer aluminum foil current collectors in power battery manufacturing. Full article

Friction stir spot welding (FSSW) is a novel variant of Friction Stir welding (FSW), developed by Mazda Motors and Kawasaki Heavy Industries to join similar and dissimilar materials in a solid state. It is an economic and environmentally friendly alternative to resistance spot welding (RSW). The FSSW technique, however, includes some structural defects imbedded within the weld joint, such as keyhole formation, hook crack, and bond line oxidation challenging the joint strength. The unique properties of nanomaterials in the reinforcement of metal matrices motivated researchers to enhance the FSSW joints’ strength. Previous studies successfully fabricated nano-reinforced FSSW joints. At different volumetric ratios of nano-reinforcement, nanoparticles may agglomerate due to inefficient stirring of the welding tool pin, forming stress concentration sites and brittle phases, affecting tensile and fatigue strength under static and cyclic loading conditions, respectively. This work investigated how the welding tool pin affects stirring efficiency by controlling the distribution of a nano-reinforcing material within the joint stir zone (SZ), and thus the tensile and fatigue strength of the FSSW joints. Sheets of AA6061-T6 of 1.8 mm thickness were used as a base material. In addition, graphene nanoplatelets (GNPs) with lateral sizes of 1–10 µm and thicknesses of 3–9 nm were used as nano-reinforcements. GNP-reinforced FSSW specimens were prepared and successfully fabricated. Optical microscope (OM) and field emission scanning electron microscope (FE-SEM) methods were employed to visualize the GNPs’ incorporation into the SZs of the FSSW joints. Micrographs of as-welded specimens showed lower formations of scattered, clustered GNPs achieved by the threaded pin tool compared to continuous agglomerations observed when the cylindrical pin tool was used. Tensile test results revealed a significant improvement of about 30% exhibited by the threaded pin tool compared to the cylindrical pin tool, while fatigue test showed an improvement of 46–24% for the low- and high-cycle fatigue, respectively. Full article

The traditional ultrasonic bonding technique for IGBT T2 copper terminals often causes physical damage to ceramic substrates, severely compromising the reliability of power modules. Meanwhile, T2 copper laser welding faces inherent challenges including low laser absorption efficiency and unstable molten pool dynamics. To address these issues, this study targets the high-quality connection of IGBT T2 copper terminals and proposes a welding solution integrating a Fiber-Diode Hybrid Laser system with galvo-scanning technology. Comparative experiments between galvo-scanning and traditional oscillation methods CNC scanning were conducted under sinusoidal and circular trajectories to explore the regulation mechanism of welding quality. The results demonstrate that CNC scanning lacks precision in thermal input control, resulting in inconsistent welding quality. Galvo-scanning enables precise modulation of laser energy distribution and molten pool behavior, effectively reducing spatter and porosity defects. It also promotes the transition from columnar grains to equiaxed grains, significantly refining the weld microstructure. Under the sinusoidal trajectory with a welding speed of 20 mm/s, the Lap-shear strength of the galvo-scanned joint reaches 277 N/mm², outperforming all CNC-scanned joints. This research proposes a non-contact welding strategy targeted at eliminating the mechanical failure mechanism associated with conventional ultrasonic bonding of ceramic substrates. It establishes the superiority of galvo-scanning for precision welding of high-reflectivity materials and lays a foundation for its potential application in new energy vehicle power modules and microelectronic packaging. Full article

The self-riveting friction stir lap welding (SRFSLW) method was utilized to improve the bonding strength of lap welding joints with medium-thick aluminum/steel plates and to realize structural lightweighting. The effect of plunge depth on the shear force and the microstructure of the joint was studied, and the influence of groove structure (rectangular groove and dovetail groove) on the failure behavior of the joint under shear load was obtained, simultaneously. The EBSD results indicate that the aluminum alloy grains in the stir zone (SZ) of groove joints have been refined compared to the non-groove joint. Meanwhile, due to the presence of grooves, the proportion of high-angle grain boundaries of the SZ is increased, and more dynamic recrystallization has emerged; thus, the KAM value of the SZ is reduced to a certain extent. The non-groove joint exhibits {111}//ND fiber texture, while the groove joint shows F-plate texture. In self-riveting joints, due to the increased metallurgical bonding area and the weakened effect of external loads, the failure of metallurgical bonding in the joint requires higher external load, and the separation of the self-riveted structure from the groove requires greater bending moment, thereby improving the strength of the joint. Full article