Search Results (18)

This study investigates the fracture toughness of adhesive joints between carbon fiber-reinforced polymer composites (CFRP) and boron-alloyed high-strength steel under Mode I and II loading, based on linear elastic fracture mechanics (LEFM). Two adhesive types were examined: the excess resin from the prepreg composite, forming a thin layer, and a toughened structural epoxy (Sika Power-533), designed for the automotive industry, forming a thick layer. Modified double cantilever beam (DCB) and end-notched flexure (ENF) specimens were used for testing. The results show that using Sika Power-533 increases the critical energy release rate by up to 30 times compared to the prepreg resin, highlighting the impact of adhesive layer thickness. Joints with the thick Sika adhesive performed similarly regardless of whether uncoated or Al–Si-coated steel was used, indicating the composite/Sika interface as the failure point. In contrast, the thin resin adhesive layer exhibited poor bonding with uncoated steel, which detached during sample preparation. This suggests that, for thin layers, the resin/steel interface is the weakest link. These findings underline the importance of adhesive selection and layer thickness for optimizing joint performance in composite–metal hybrid structures. Full article

This study employed novel joint treatments to strengthen the carbon fiber reinforced polymer (CFRP) composites. Vertically aligned carbon nanotubes (VACNTs) were prepared in situ on the catalyst-treated CF surface via the chemical vapor deposition (CVD) method, intertwining into three-dimensional fiber-nets and fully surrounding CF to form an integrated structure. The resin pre-coating (RPC) technique was further used to guide diluted epoxy resin (without hardener) to flow into nanoscale and submicron spaces to eliminate void defects at the root of VACNTs. Three-point bending testing results showed the “growing CNTs and RPC”-treated CFRP composites yielded the best flexural strength, a 27.1% improvement over the specimens without treatment, while the failure modes indicated that the original delamination failure was changed into “flexural failure” with through-the-thickness crack propagation. In brief, growing VACNTs and RPC on the CF surface enabled toughening of the epoxy adhesive layer, reducing potential void defects and constructing the integrated quasi-Z-directional fiber bridging at the CF/epoxy interface for stronger CFRP composites. Therefore, the joint treatments of growing VACNTs in situ via the CVD method and RPC technique are very effective and have great potential in manufacturing high-strength CFRP composites for aerospace applications. Full article

The demand for ever-lighter structures raises the interest in bonding as a joining method, especially for materials that are difficult to join with traditional welding and bolting techniques. Structural adhesives, however, are susceptible to defects, but can be toughened in several ways: by changing their chemical composition or by adding fillers, even of nanometric size. Nanomaterials have a high surface area and limited structural defects, which can enhance the mechanical properties of adhesives depending on their nature, quantity, size, and interfacial adhesion. This work analyzes the Mode I fracture toughness of joints bonded with METLBOND^® 1515-4M epoxy film and XantuLayr electrospun XD 10 polyamide nanofibers. Two joint configurations were studied, which differed according to the position of the nanomat within the adhesive layer: one had the nanofibers at the substrate/adhesive interfaces, and the other had the nanofibers in the center of the adhesive layer. Double cantilever beam joints were manufactured to evaluate the Mode I fracture toughness of the bonding with and without nano-reinforcement. The nanofibers applied at the substrate/adhesive interface improved the Mode-I fracture toughness by 32%, reaching the value of 0.55 N/mm. SEM images confirm the positive contribution of the nanofibers, which appear stretched and pulled out from the matrix. No fracture toughness variation was detected in the joints with the nanofibers placed in the middle of the adhesive layer. Full article

Epoxy resin has a tight three-dimensional mesh structure after curing; due to this reason, the epoxy resin is brittle and not tough enough, which becomes the main reason for the destruction of the epoxy adhesive-steel/CFRP interface under fatigue loading of CFRP-reinforced steel structures. To prepare epoxy adhesives with good performance and suitable for CFRP-reinforced steel structures, the mechanical properties of epoxy adhesives are improved by adding polystyrene (PS) microspheres. In this work, five modified adhesives with PS weight fractions of 0 wt%, 1.25 wt%, 2.50 wt%, 3.75 wt% and 5 wt% are prepared by dispersion of PS particles through an ultrasonic cell crusher using a room-temperature curing process, and the tensile, flexural and impact properties of PS adhesives with different doping are investigated. Then, the microscopic morphology of the tensile section of the colloids is observed by scanning electron microscopy (SEM). The results show that the optimum dosing of PS is 2.5 wt%, and the tensile strength, tensile modulus of elasticity, flexural strength, flexural modulus and impact strength of the adhesive are increased by 77%, 147.7%, 71%, 35% and 22%, respectively, with this dosing. SEM analysis shows that PS particles produce large deformation to absorb energy when the matrix is fractured, and crack expansion needs to bypass or shear the PS particles, thus inhibiting crack expansion and achieving the purpose of toughening. Adhesion agglomeration of PS particles in the resin is the main reason for the decrease in the mechanical properties of adhesives. Full article

Bismaleimide (BMI) resin-based structural adhesives have excellent heat resistance, with important applications demonstrated in the bonding of high-temperature BMI composites. In this paper, we report an epoxy-modified BMI structural adhesive with excellent properties for bonding BMI-based CFRP. We prepared the BMI adhesive using epoxy-modified BMI as the matrix and PEK-C and core–shell polymers as synergistic tougheners. We found that the epoxy resins improve the process and bonding properties of BMI resin but slightly reduce thermal stability. PEK-C and core–shell polymers synergistically improve the toughness and bonding performances of the modified BMI adhesive system and allow the maintenance of heat resistance. The optimized BMI adhesive exhibits excellent heat resistance, with a high glass transition temperature of 208.6 °C and a high thermal degradation temperature of 425.4 °C. Most importantly, the optimized BMI adhesive exhibits satisfactory intrinsic bonding and thermal stability. It has a high shear strength of 32.0 MPa at room temperature and up to 17.9 MPa at 200 °C. The BMI adhesive-bonded composite joint has a high shear strength of 38.6 and 17.3 MPa at room temperature and 200 °C, respectively, indicating effective bonding and excellent heat resistance. Full article

The interfacial designing of carbon fiber (CF)/epoxy composites, as a well-accepted method used to obtain high-performance composites, has gained extensive attention. However, an improvement in interfacial adhesion is usually accompanied by a simultaneous decrease in toughness, which has become an obstacle to the performance enhancement of CF/epoxy composites. Herein, nanosized UiO-66-NH₂ was proposed to yield on the CF surface through an in situ growth method for preparing high-performance CF/epoxy composites. The induced UiO-66-NH₂ could significantly enhance the active groups, surface roughness and wettability on the fiber surface, which can be confirmed by XPS, FTIR, dynamic contact angle (DCA) and SEM. Moreover, the porous structure of UiO-66-NH₂ enables the epoxy resin to pass through it, which could toughen the matrix by forming an interpenetrating network structure and reducing the density of resin crosslinking. Meanwhile, the size effect of UiO-66-NH₂ could hinder the crack propagation and release the stress concentration. Benefiting from these interfacial strengthening and toughening effects, the interlaminar shear strength and impact strength increased by 44.2% and 27.6%, respectively, in comparison to those of untreated CF. This work proposes a simple and effective strategy for interfacial designing that could offer new ideas for solving the conflict between the strengthening and toughening and provide a practical basis for preparing high-performance resin matrix composites. Full article

When the thermoplastic composites reach the service limits during the service, the recovery and utilization are the key concerns. Meanwhile, the improvement of strength, toughness and durability of epoxy resin is the effective method to prolong the service life of materials and structures. In the present paper, three kinds of thermoplastic resins (polypropylene-PP, polyamide 6-PA6 and polyether-ether-ketone-PEEK) and composites (carbon fiber-PEEK, glass fiber-PA6 and glass fiber-PP) were adopted as the fillers to reinforce and toughen the epoxy resin (Ts). The mechanical, thermal and microscopic analysis were conducted to reveal the performance improvement mechanism of Ts. It can be found that adding thermoplastic resin and composite fillers at the low mass ratio of 0.5~1.0% brought about the maximum improvement of tensile strength (7~15%), flexural strength (7~15%) and shear strength (20~30%) of Ts resin. The improvement mechanism was because the addition of thermoplastic fillers can prolong the cracking path and delay the failure process through the load bearing of fiber, energy absorption of thermoplastic resin and superior interface bonding. In addition, the thermoplastic composite had better enhancement effect on the mechanical/thermal properties of Ts resin compared to thermoplastic resin. When the mass ratio was increased to 2.0~3.0%, the agglomeration and stress concentration of thermoplastic filler in Ts resin appeared, leading to the decrease of mechanical and thermal properties. The optimal addition ratios of thermoplastic resin were 0.5~1.0% (PEEK), 1.0~2.0% (PA6) and 0.5~1.0% (PP) to obtain the desirable property improvement. In contrast, the optimal mass ratios of three kinds of composite were determined to be 0.5~1.0%. Application prospect analysis indicated adding the thermoplastic resin and composite fillers to Ts resin can promote the recycling and reutilization of thermoplastic composites and improve the performance of Ts resin, which can be used as the resin matrix, interface adhesive and anti-corrosion coating. Full article

The thermally conductive structural film adhesive not only carries large loads but also exhibits excellent heat-transfer performance, which has huge application prospects. Herein, a novel epoxy (Ep) thermally conductive structural film adhesive was prepared using polyphenoxy (PHO) as the toughening agent and film former, boron nitride (BN) nanosheets as the thermally conductive filler, and polyester fabric as the carrier. When the amount of PHO in the epoxy matrix was 30 phr and the content of nano-BN was 30 wt.% (Ep/PHO30/nBN30), the adhesive resin system showed good film-forming properties, thermal stability, and thermal conductivity. The glass transition temperature of Ep/PHO30/nBN30 was 215 °C, and the thermal conductivity was 209.5% higher than that of the pure epoxy resin. The Ep/PHO30/nBN30 film adhesive possessed excellent adhesion and peeling properties, and the double-lap shear strength at room temperature reached 36.69 MPa, which was 21.3% higher than that of pure epoxy resin. The double-lap shear strength reached 15.41 MPa at 150 °C, demonstrating excellent high temperature resistance. In addition, the Ep/PHO30/nBN30 film adhesive exhibited excellent heat-aging resistance, humidity, and medium resistance, and the shear strength retention rate after exposure to the complicated environment reached more than 90%. The structural film adhesive prepared showed excellent fatigue resistance in the dynamic load fatigue test, the double-lap shear strength still reached 35.55 MPa after 1,000,000 fatigue cycles, and the strength retention rate was 96.9%, showing excellent durability and fatigue resistance. Full article

Epoxy resin with excellent mechanical properties, chemical stability, and corrosion resistance has been widely used in automotive and aerospace industries. A thin film of epoxy deposited on a substrate has great application in adhesive bonding and protective coating. However, the intrinsic brittleness of epoxy with a relatively low fracture toughness limits its applications. In this work, graphene nanoplatelets (GNP) were added to the epoxy resin to enhance its toughness, hardness, and elastic modulus. A series of nanocomposites with different loadings of GNP were fabricated. Ultrasonic sonication in combination with surfactant Triton X-100 were employed to disperse GNP in the epoxy matrix. A nanocomposite film with a thickness of 0.3 mm was deposited on an Al substrate using a spinning coating technology. The hardness and elastic modulus of the nanocomposite film on the Al substrate were experimentally measured by a nanoindentation test. Analytical expression of the mode II interfacial fracture toughness for the nanocomposite film on an Al substrate with an interfacial edge crack was derived utilizing the linear elastic fracture mechanics and Euler’s beam theory. End-notched flexure (ENF) tests were conducted to evaluate the mode II fracture toughness. It was found that the hardness, elastic modulus, and mode II fracture toughness of the nanocomposite film reinforced with 1 wt % of GNP were improved by 71.8%, 63.2%, and 44.4%, respectively, compared with the pure epoxy. The presence of much stiff GNP in the soft epoxy matrix prompts toughening mechanisms such as crack deflection and crack pinning, resulting in the improvements of the fracture toughness, hardness, and elastic modulus. Microscopic observation for the nanocomposite was examined by scanning electron microscopy (SEM) to investigate the dispersion of GNPs in the epoxy matrix. The performance of a nanocomposite film deposited on a substrate was rarely studied, in particular, for the interfacial fracture toughness of the film/substrate composite structure. Utilizing the theoretical model in conjunction with the ENF experimental test presented in this study, an accurate determination of the mode II interfacial fracture toughness of film/substrate composite structure is made possible. Full article

Adhesive bonding of carbon-fiber-reinforced polymers (CFRPs) is a key enabling technology for the assembly of lightweight structures. Surface pretreatment is necessary to remove contaminants related to material manufacturing and ensure bond reliability. The present experimental study focuses on the effect of mechanical abrasion on the damage mechanisms and fracture toughness of CFRP/epoxy joints. The analyzed CFRP plates were provided with a thin layer of surface epoxy matrix and featured enhanced sensitivity to surface preparation. Various degrees of morphological modification and fairly controllable carbon fiber exposure were obtained using sanding with emery paper and grit-blasting with glass particles. In the sanding process, different grit sizes of SiC paper were used, while the grit blasting treatment was carried by varying the sample-to-gun distance and the number of passes. Detailed surveys of surface topography and wettability were carried out using various methods, including scanning electron microscopy (SEM), contact profilometry, and wettability measurements. Mechanical tests were performed using double cantilever beam (DCB) adhesive joints. Two surface conditions were selected for the experiments: sanded interfaces mostly made of a polymer matrix and grit-blasted interfaces featuring a significant degree of exposed carbon fibers. Despite the different topographies, the selected surfaces displayed similar wettability. Besides, the adhesive joints with sanded interfaces had a smooth fracture response (steady-state crack growth). In contrast, the exposed fibers at grit-blasted interfaces enabled large-scale bridging and a significant R-curve behavior. While it is often predicated that quality composite joints require surfaces with a high percentage of the polymer matrix, our mechanical tests show that the exposure of carbon fibers can facilitate a remarkable toughening effect. These results open up for additional interesting prospects for future works concerning toughening of composite joints in automotive and aerospace applications. Full article

Automotive structural adhesives must show a steady toughness performance in the temperature range of −40 °C to 80 °C, considering their actual usage environments. Core-shell rubber (CSR) nanoparticles are known to enhance the toughness of epoxy systems. In this study, a CSR, pre-dispersed, diglycidyl epoxy of bisphenol A (DGEBA) mixture at 35 wt % (KDAD-7101, Kukdo Chemical, Seoul, Korea) was used as a toughener for an automotive structural epoxy adhesive system. A simple, single-component, epoxy system of DGEBA/dicyandiamide with a latent accelerator was adopted, where the CSR content of the system was controlled from 0 to 50 phr by the CSR mixture. To determine the curing conditions, we studied the curing behavior of the system by differential scanning calorimetry (DSC). Modulus variations of the cured bulk epoxies were studied using a dynamic mechanical analyzer (DMA) in the dual cantilever mode. The flexural modulus of the cured epoxies at various temperatures (−40, −10, 20, 50, and 80 °C) showed the same tendency as the DMA results, and as the flexural strength, except at 0 phr. On the other hand, the strain at break exhibited the opposite tendency to the flexural modulus. To study the adhesion behavior, we performed single-lap joint (SLJ) and impact wedge-peel (IWP) tests. As the CSR content increased, the strength of the SLJ and dynamic resistance to the cleavage of the IWP improved. In particular, the SLJ showed excellent strength at low temperatures (32.74 MPa at 50 phr @ −40 °C (i.e., an 190% improvement compared to 17.2 MPa at 0 phr @ −40 °C)), and the IWP showed excellent energy absorption at high temperatures (21.73 J at 50 phr @ 80 °C (i.e., a 976% improvement compared to 2.07 J at 0 phr @ 80 °C)). The results were discussed in relation to the changes in the properties of the bulk epoxy depending on the temperature and CSR content. The morphology of the fracture surface was also provided, which offered useful information for composition studies using the CSR/epoxy system. Full article

Epoxy structural adhesives have strong adhesion, minimal shrinkage and high thermal and chemical resistance. However, despite these excellent properties, their high-energy impact resistance should be improved to satisfy the increasing demands of the automotive industry. For this reason, we used four types of silica nanoparticles with different surface groups, such as polydimethylsiloxane (PDMS), hydroxyl, epoxy and amine groups, as toughening agents and examined their effect on the glass transition temperature (T_g), crosslinking density and phase separation of epoxy structural adhesives. High-energy impact resistance, mode I fracture toughness and lap shear strength were also measured to explain the effect of surface functional groups. Silica nanoparticles with reactive functional groups increased the mode I fracture toughness of epoxy structural adhesives without sacrificing the crosslinking density. Although the mode I fracture toughness of epoxy structural adhesives could not clearly show the effect of surface functional groups, the dynamic resistance to cleavage obtained by impact wedge-peel tests showed quite different values. At a 0.3 vol% content, epoxy-functionalized silica nanoparticles induced the highest value (40.2 N/mm) compared to PDMS (34.1 N/m), hydroxyl (34.9 N/mm), and amine (36.1 N/m). All of these values were significantly higher than those of pristine epoxy structural adhesive (27.7 N/mm). Full article

Epoxy adhesives are widely used in various industries because of their high heat and chemical resistance, high cohesion, and minimal shrinkage. Recently, epoxy adhesives have been applied in the automotive industry as structural adhesives for lightweight vehicles. However, the brittleness of the epoxy is an obstacle for this application, since the automotive industry requires epoxy-based structural adhesives to have a high level of high-speed impact resistance. Hence, we used phenol-terminated polyurethane (PTPU) as a toughening agent for epoxy adhesives and compared the results with those that were obtained with carboxyl-terminated butadiene acrylonitrile copolymer (CTBN). The high-energy impact resistance of the epoxy adhesives was measured by the impact wedge-peel (IWP) test, and the shear strength was measured by the single lap joint test. As a result, the 20 wt % PTPU-modified epoxy adhesive showed remarkably higher total absorbed energy (25.8 J) during the IWP test and shear strength (32.3 MPa) as compared with the control epoxy adhesive (4.1 J and 20.6 MPa, respectively). In particular, the total absorbed energy of the PTPU-modified epoxy adhesive was much larger than that of the CTBN-modified epoxy adhesive (5.8 J). When more than 10 wt % PTPU was added, the modified epoxy adhesives showed stable crack growth and effectively transferred external stress to the substrate. These results were explained by changes in the glass transition temperature, crosslinking density, and morphology due to the toughening agents. Full article

The focus of our study is to identify physical properties of different impact-resistant/toughened structural adhesives and identify/develop an elastic-viscoelastic-plastic model as a function of loading rate by using Ludwik-type equations to be able to predict adhesive behavior at higher loading rates and to make cars more crashworthy. For this purpose, we first characterized eight different commercial toughened epoxy structural adhesives to provide detailed information about their constituents using X-ray diffraction (XRD), differential thermal analysis (DTA), thermogravimetric analysis (TGA), scanning electron microscope (SEM) and energy dispersive x-ray spectrometer (EDS). Most (but not all) of the model adhesives contained organic tougheners in the form of carboxyl terminated butadiene acrylonitrile (CTBN) copolymer, as well as polyurethane adducts. The main crystalline inorganic phases were found as calcite (CaCO₃), wollastonite (CaSiO₃) or calcium silicate (CaSiO₃), talc (Mg₃Si₄O₁₀ (OH)₂), zeolite which is an alumina silicate based mineral and has many different elements in its composition (M₂/nO·Al₂O₃·xSiO₂·yH₂O, M can be Mg, Na, Ca, K, Li). The total amount of inorganic fillers was found to be different in each adhesive. Material behavior of the model adhesives were determined via tensile tests and Single Lap Joint (SLJ) tests in shear. Split Hopkinson pressure bar (SHPB) was also used to measure the strain and stress values at higher strain rates in the order of 10² s⁻¹, which is generally encountered in impact related loading situations. Toughness values in the range ~0.5 to ~1.35 MJ/m³ were observed with the model adhesives tested in tensile mode within the ~3 × 10⁻³ to 0.18 m/m/s strain rate range. The softening behavior of the elastic moduli at higher strain rates observed during tensile testing was also observed with SHPB testing. It is remarkable that, overall, the modulus magnitudes seem to be similar between the tensile test and SHPB specimens within this softening range of the initial bilinear elastic behavior observed. When the results from bulk (tensile) and bonded (shear) specimens were compared, it was clearly seen that the toughness responses of the adhesives to (tensile/shear) strain rates in the bulk and bonded forms, respectively, were different, with the bonded shear toughness values in the ~25 to ~120 MJ/m³ range within ~1.25 to ~25 mm/mm/s shear strain range. The model adhesive which included just inorganic fillers had the lowest tensile toughness at the lowest tensile strain rate, but the highest slope in its tensile toughness regression line, exhibited the second highest bonded shear toughness. When tested at the extension rates of 25 mm/min and 100 mm/min in bonded lap shear, the same adhesive exhibited limited interfacial failure areas, however the dominant failure mode was cohesive failure. When the extension rate increased further, transition to interfacial (adhesive) failure was observed revealing that interfacial failures do not necessarily diminish adhesive bond toughness. Our observations point to the fact that cohesive deformation/failure processes indicating interfacial separations, inter-particle interactions as well as polymer matrix deformation in high deformation loading scenario as in bonded shear loadings may provide the highest toughness. Apparently, a large inorganic filler weight fraction is not necessary to obtain high shear toughness in bonded form since the highest bonded shear toughness was obtained with the adhesive which had the least amount of inorganic fillers among the model adhesives with 14.72 wt %. Full article

In order to improve the interfacial properties of graphene oxide (GO) and epoxy resin (EP), hyperbranched polyesters with terminal carboxyl (HBP) non-covalently functionalized graphene oxide (HBP-GO) was achieved by strong π-π coupling between hyperbranched polyesters and GO nanosheets. The effects of non-covalent functionalization of GO on the dispersibility, wettability and interfacial properties were analyzed. The mechanical properties and enhancement mechanism of HBP-GO/EP composites were investigated. The results show that the hyperbranched polyesters is embedded in the GO layer due to its highly branched structure, which forms the steric hindrance effect between the GO nanosheets, effectively prevents the agglomeration of GO nanosheets, and significantly improved the dispersibility of GO. Simultaneously, the contact angle of HBP-GO with EP is reduced, the surface energy, interfacial energy and adhesion work are increased, then the wetting property of HBP-GO is significantly improved. The main toughening mechanism of HBP-GO is microcrack deflection induced by HBP-GO and plastic deformation of the EP matrix. In the microcrack propagation zones, HBP-GO may produce the pinning effect near the microcrack tips and change their stress state, resulting in microcrack deflection and bifurcation. So, the microcrack propagation path is more tortuous, which will consume much more fracture energy. Therefore, the mechanical properties of the HBP-GO/EP composites are greatly improved. Full article