Influence of Physical Modification of the Adhesive Composition on the Strength Properties of Aerospace Aluminum Alloy Sheet Adhesive Joints

One of the most important design factors in the constitution of adhesive joints is the correct choice of adhesive. Currently, there is a full range of options on the commercial market in this regard, but there is increasing research into modifying adhesives for specific engineering applications. The aim of this study was to analyze the effect of physical modification with fillers on the properties of the adhesive composition and the adhesive joints. The adhesives used in the study were a composition of Epidian 5 epoxy resin and PAC curing agent modified with 1% montmorillonite, 5% calcium carbonate and 20% activated carbon. The adhesive compositions in the cured state were subjected to strength tests and SEM and DSC analyses. Using these compositions, adhesive joints of EN AW 2024 T3 aluminum alloy sheets were also made. The tests carried out showed that, due to the use of different fillers, their effects on certain properties of the adhesive compositions are different types. It was shown that physical modification of the adhesive composition does not always result in positive effects. The study also attempted to determine the correlation between the properties of the adhesive compositions in the cured state and the strength of the adhesive joints.     

Multi-Criteria Optimisation of Friction Stir Welding Parameters for EN AW-2024-T3 Aluminium Alloy Joints

The aim of this research was the selection of friction stir welding (FSW) parameters for joining stiffening elements (Z-stringers) to a thin-walled structure (skin) made of 1 mm-thick EN AW-2024 T3 aluminium alloy sheets. Overlapping sheets were friction stir welded with variable values of welding speed, pin length (plunge depth), and tool rotational speed. The experimental research was carried out based on a three-factor three-level full factorial Design of Experiments plan (DoE). The load capacity of the welded joints was determined in uniaxial tensile/pure shear tests. Based on the results of the load capacity of the joint and the dispersion of this parameter, multi-criteria optimisation was carried out to indicate the appropriate parameters of the linear FSW process. The optimal parameters of the FSW process were determined based on a regression equation assessed by the Fisher–Senecor test. The vast majority of articles reviewed concern the optimisation of welding parameters for only one selected output parameter (most often joint strength). The aim of multi-criteria optimisation was to determine the most favourable combination of parameters in terms of both the smallest dispersion and highest load capacity of the joints. It was found that an increase in welding speed at a given value of pin length caused a decrease in the load capacity of the joint, as well as a significant increase in the dispersion of the results. The use of the parameters obtained as a result of multi-criteria optimisation will allow a minimum load capacity of the joints of 5.38 kN to be obtained with much greater stability of the results.     

The Influence of Tool Shape and Process Parameters on the Mechanical Properties of AW-3004 Aluminium Alloy Friction Stir Welded Joints

The purpose of the following study was to compare the effect of the shape of a tool on the joint and to obtain the values of Friction Stir Welding (FSW) parameters that provide the best possible joint quality. The material used was an aluminium alloy, EN AW-3004 (AlMn1Mg1). To the authors’ best knowledge, no investigations of this alloy during FSW have been presented earlier. Five butt joints were made with a self-developed, cylindrical, and tapered threaded tool with a rotational speed of 475 rpm. In order to compare the welding parameters, two more joints with a rotational speed of 475 rpm and seven joints with a welding speed of 300 mm/min with the use of a cylindrical threaded pin were performed. This involved a visual inspection as well as a tensile strength test of the welded joints. It was observed that the value of the material outflow for the joints made with the cylindrical threaded pin was higher than it was for the joints made with the tapered threaded pin. However, welding defects in the form of voids appeared in the joints made with the tapered threaded tool. The use of the cylindrical tool resulted in higher values for about 37% of mechanical properties compared with the highest result for the tapered threaded joint. As far as the parameters were concerned, it was concluded that most of the specimens were properly joined for a rotational speed of 475 rpm. In the joints made with a welding speed of 300 mm/min, the material was not stirred properly. The best joint quality was given for a rotational speed of 475 rpm as well as a variety of welding speed values between 150 and 475 mm/min.     

Research on the Influence of the AW 5754 Aluminum Alloy State Condition and Sheet Arrangements with AW 6082 Aluminum Alloy on the Forming Process and Strength of the ClinchRivet Joints

Clinching joints with an additional deformable rivet are modifications of the clinching joints. The clinch riveting (CR) joint is formed indirectly by a deformable rivet. The research included an analysis of CR joints’ forming process for aluminum alloy sheets made of AW 6082 in T6 state condition and AW 5754 in three different state conditions: H11, H22 and H24. As a result of forming the joint for various sheet arrangements, the highest value of blocking the upper sheet in the lower sheet (t_u) was obtained for the arrangements with two 5754-H24 aluminum alloy sheets. For such a large interlock parameter t_u, the greatest thinning of lower sheet (t_n) was obtained, which influenced the maximum tensile shear force and the joint failure mechanism. Based on the load-displacement diagrams obtained from the static shear test of lap joints, the total energy of failure and energy to achieve the maximum load capacity were calculated. The highest energy absorption to achieve the maximum load capacity, in the case of the same sheet materials, was obtained for the 5754-H11 aluminum alloy sheets. On the other hand, among the tested combinations, the highest value of energy absorption (for the joint maximum load capacity) was obtained for the sheet arrangement: top sheet AW 6082-T6 and the bottom AW 5754-H24. The highest value of the total energy up to fracture was obtained when the material of the top sheet was AW 6082-T6, and the bottom AW 5754-H22. For each sheet arrangement, a similar analysis of the joint strength parameters, interlock parameters and forming force were made.     

Influence of Surface Treatment on Steel Adhesive Joints Strength—Varnish Coats

The purpose of the paper is to determine the impact of surface treatment on the strength of adhesive joints, made from various steel sheets. Two variants of the surface treatment steel adherends were used: without the varnish coat and with the varnish coat, using three polymer-based varnishes (a simple, a hybrid, and a gel). Two types of the adhesives were used to prepare the adhesive joints: a single-component cyanoacrylate adhesive and a two-component epoxy adhesive. A strength test of the adhesive joints (EN DIN 1465 standard), a coating adhesion test (ASTM D3359-B standard), and surface topography, as well as surface roughness, parameters (PN-EN ISO 11562, PN-EN ISO 4287, and PN-EN ISO 25178 standards) were used. Based on the strength tests, it was observed that the adhesive joints, with the hybrid varnish onto the adherend’s surface, achieved markedly lower shear strength. The best results, in terms of the adhesive joint strength, made using the cyanoacrylate adhesive were achieved for the joints where the adherends were coated with a simple varnish, while in the joints made using the epoxy adhesive, the highest shear strength was achieved by the joints of sheets whose surfaces were coated with the gel varnish.     

The Effect of Adhesive Layer Thickness on Joint Static Strength

One of the most relevant geometrical factors defining an adhesive joint is the thickness of the adhesive layer. The influence of the adhesive layer thickness on the joint strength has not been precisely understood so far. This article presents simplified analytical formulas for adhesive joint strength and adhesive joint coefficient for different joint loading, assuming, inter alia: linear-elastic strain of adhesive layer, elastic strain of adherends and only one kind of stress in adhesive. On the basis of the presented adhesive joint coefficient, the butt joint was selected for the tests of the influence of adhesive thickness on the adhesive failure stress. The tests showed clearly that with an increase in the thickness of the tested adhesive layers (up to about 0.17 mm), the value of their failure stress decreased quasi linearly. Furthermore, some adhesive joints (inter alia subjected to shearing) may display the optimum value of the thickness of the adhesive layer in terms of the strength of the joint. Thus, the aim of this work was to explain the phenomenon of optimal adhesive layer thickness in some types of adhesive joints. The verifying test was conducted with use of single simple lap joints. Finally, with the use of the FE method, the authors were able to obtain stresses in the adhesive layers of lap joints for loads that destroyed that joints in the experiment, and the FEM-calculated failure stresses for lap joints were compared with the adhesive failure stresses determined experimentally using the butt specimens. Numerical calculations were conducted with the use of the continuum mechanics approach (stress-based), and the non-linear behavior of the adhesive and plastic strain of the adherends was taken into account.     

Investigation into the Effect of RFSSW Parameters on Tensile Shear Fracture Load of 7075-T6 Alclad Aluminium Alloy Joints

The aim of the investigations was to determine the effect of parameters of refill friction stir spot welding (RFSSW) on the fracture load and failure mechanisms of the resulting joint. RFSSW joints were made in 7075-T6 Alclad aluminium alloy sheets using different welding parameters. The load capacity of joints was determined under tensile/shear loadings. Finite element-based numerical simulations of the joint-loading process were carried out, taking into account the variability of elasto-plastic properties of weld material through the joint cross-section. The influence of welding parameters on selected phenomena occurring during the destruction of the joint is presented. The considerations were supported by a fractographic analysis based on SEM images of fractures. It was found that there is a certain optimal amount of heat generated, which is necessary to produce the correct joint in terms of its load capacity. This value should not be exceeded, because it leads to weakening of the base material and thus to a reduction in the strength of the joint. Samples subjected to uniaxial tensile shear load showed three types of failure mode (tensile fracture, shear fracture, plug type fracture) depending on the tool rotational speed and duration of welding. Prediction of the fracture mode using FE-based numerical modelling was consistent with the experimental results. The samples that were damaged due to the tensile fracture of the lower sheet revealed a load capacity (LC) of 5.76 KN. The average value of LC for the shear fracture failure mechanism was 5.24 kN. The average value of the LC for plug-type fracture mode was 5.02 kN. It was found that there is an optimal amount of heat generated, which is necessary to produce the correct joint in terms of its LC. Excessive overheating of the joint leads to a weakening of the base metal and thus a reduction in the strength of the joint. Measurements of residual stresses along the axis specimens showed the presence of stresses with a certain constant value for the welded area on the side of the 1.6 mm thick plate.     

Influence of Tool Geometry and Process Parameters on the Properties of Friction Stir Spot Welded Multiple (AA 5754 H111) Aluminium Sheets

Friction stir spot welding is an emerging spot-welding technology that offers opportunities for joining a wide range of materials with minimum energy consumption. To increase productivity, the present work addresses production challenges and aims to find solutions for the lap-welding of multiple ultrathin sheets with maximum productivity. Two convex tools with different edge radii were used to weld four ultrathin sheets of AA5754-H111 alloy each with 0.3 mm thickness. To understand the influence of tool geometries and process parameters, coefficient of friction (CoF), microstructure and mechanical properties obtained with the Vickers microhardness test and the small punch test were analysed. A scanning acoustic microscope was used to assess weld quality. It was found that the increase of tool radius from 15 to 22.5 mm reduced the dwell time by a factor of three. Samples welded with a specific tool were seen to have no delamination and improved mechanical properties due to longer stirring time. The rotational speed was found to be the most influential parameter in governing the weld shape, CoF, microstructure, microhardness and weld efficiency. Low rotational speeds caused a 14.4% and 12.8% improvement in joint efficiency compared to high rotational speeds for both tools used in this investigation.     

Surface Finish Analysis in Single Point Incremental Sheet Forming of Rib-Stiffened 2024-T3 and 7075-T6 Alclad Aluminium Alloy Panels

The article presents the results of the analysis of the interactions between the single point incremental forming (SPIF) process parameters and the main roughness parameters of stiffened ribs fabricated in Alclad aluminium alloy panels. EN AW-7075-T6 and EN AW-2024-T3 Alclad aluminium alloy sheets were used as the research material. Panels with longitudinal ribs were produced with different values of incremental vertical step size and tool rotational speed. Alclad is formed of high-purity aluminium surface layers metallurgically bonded to aluminium alloy core material. The quality of the surface roughness and unbroken Alclad are key problems in SPIF of Alclad sheets destined for aerospace applications. The interactions between the SPIF process parameters and the main roughness parameters of the stiffened ribs were determined. The influence of forming parameters on average roughness Sa and the 10-point peak–valley surface roughness Sz was determined using artificial neural networks. The greater the value of the incremental vertical step size, the more prominent the ridges found in the inner surface of stiffened ribs, especially in the case of both Alclad aluminium alloy sheets. The predictive models of ANNs for the Sa and the Sz were characterised by performance measures with R² values lying between 0.657 and 0.979. A different character of change in surface roughness was found for sheets covered with and not covered with a soft layer of technically pure aluminium. In the case of Alclad sheets, increasing the value of the incremental vertical step size increases the value of the surface roughness parameters Sa and Sz. In the case of the sheets not covered by Alclad, reduction of the tool rotational speed increases the Sz parameter and decreases the Sa parameter. An obvious increase in the Sz parameter was observed with an increase in the incremental vertical step size.     

The Influence of Shot Peening and Artificially Ageing Aluminium Alloy 7075 on Corrosion Behaviour

This paper investigates the corrosion of shot peened AA7075 aluminium alloys aged at different temperatures. The surface integrity of the hardened layer was evaluated with SEM, EDS, differential scanning calorimetry, hardness, and roughness measurements, and in the end also with corrosion resistance tests. The research results indicated that there were significant differences in precipitates distribution between aluminium alloys artificially aged at different temperatures. As the ageing temperature increases, the microhardness decreases, which influences the final roughness condition of the surface layer after shot peening. The results of potentiodynamic polarisation tests indicate that shot peening enables shifting the pitting potential to positive values, which ensures slightly higher corrosion resistance. SEM images confirmed the dissolution of the aluminium matrix near the separated iron-rich phases of the Al_x form (Fe, Mn) by the action of galvanic cells.     

The Influence of Background Ultrasonic Field on the Strength of Adhesive Zones under Dynamic Impact Loads

The influence of background ultrasonic field on the ultimate dynamic strength of adhesive joints is studied using fracture mechanics analysis. Winkler foundation-type models are applied to describe the cohesion zone, and the incubation time fracture criterion is used. The challenging task is to study whether relatively weak ultrasound is able to decrease the threshold values of the external impact load depending on a joint model, such as an “elastic membrane” or “beam” approximation, and various boundary conditions at the ends. The specific task was to investigate the case of short pulse loading through application of time-dependent fracture criterion instead of the conventional principle of critical stress. Three different load cases, namely, step constant force, dynamic pulse, and their combination with ultrasonic vibrations, were also studied. The analytical solution to the problem demonstrates that background vibrations at certain frequencies can significantly decrease threshold values of fracture impact load. Specific calculations indicate that even a weak background sonic field is enough to cause a significant reduction in the threshold amplitude of a dynamic short pulse load. Additionally, non-monotonic dependency of threshold amplitude on pulse duration for weak background field was observed, which demonstrates the existence of optimal regimes of impact energy input. Moreover, this phenomenon does not depend on the way in which the beam edges mount, whether they are clamped or hinged, and it could be applied for micro-electro-mechanical switch design processes as an additional tool to control operational regimes.     

Influence of Aging on Corrosion Behaviour of the 6061 Cast Aluminium Alloy

The influence of AlFeSi and Mg₂Si phases on corrosion behaviour of the cast 6061 aluminium alloy was investigated. Scanning Kelvin probe force microscopy (SKPFM), electron probe microanalysis (EPMA), and in situ observations by confocal laser scanning microscopy (CLSM) were used. It was found that Mg₂Si phases were anodic relative to the matrix and dissolved preferentially without significantly affecting corrosion propagation. The AlFeSi phases’ influence on 6061 aluminium alloy local corrosion was greater than that of the Mg₂Si phases. The corroded region width reached five times that of the AlFeSi phase, and the accelerating effect was terminated as the AlFeSi dissolved.     

Application of an Artificial Neural Network in the Modelling of Heat Curing Effects on the Strength of Adhesive Joints at Elevated Temperature with Imprecise Adhesive Mix Ratios

This paper is a discussion of the results of tests intended to (i) estimate the effects of component mix ratios and heat curing of an adhesive joint on the tensile strength, and (ii) to determine the adhesive component mix ratio for which heat curing is insignificant to the strength of adhesive butt joints. Experimental tests were carried out at ambient temperature and elevated temperature during which adhesive butt joints were loaded with a tensile force until failure. The variables were the mix ratio of epoxy adhesive components and the application of heat holding at the adhesive curing stage. An LSTM (long short-time memory) forecast was used to determine the point corresponding to the mix ratio of adhesive components at which heat holding of the adhesive joint no longer has a positive and significant importance to the final tensile strength of the joint.     

Influence of Column Axial Load and Heat Affected Zone on the Strength of Aluminium Column Web in Tension

The component method for aluminium joints has been recently introduced in some codes and guidelines. Nevertheless, it is still in need of some development and improvement, as in some cases it was obtained by adapting the existing formulations that are valid for steel. The current paper presents the main outcomes of a parametric analysis carried out by means of finite element (FE) numerical models for determining the influence of both column axial load and heat affected zone—in the case of welded details—on the structural response of the column web in a tension component. The proposed study integrates previous research carried out by the authors, where the influence of the assumed alloy was investigated and interpreted by corrective parameters expressed as a function of both the material strain hardening and ductility.     

Effect of SiC Abrasive Blasting Parameters on the Quality of the Ceramic and Ni-Cr Dental Alloy Joint

The SiC abrasive blasting parameters are vital in ensuring a suitable bond between dental ceramics and the Ni-Cr alloy. The purpose of this in vitro test was to examine the strength of the joint between the Ni-Cr alloy and fused dental ceramics for SiC abrasive blasting at a specific pressure (400, 600 kPa) and particle size (50, 110, 250 µm) in order to determine the optimal treatment parameters. The test also accounted for thermal loads (5000 cycles, 5–55 °C) to which the metal-ceramic joint is subjected during use. One hundred and forty-four Ni-Cr cylinders were divided into six groups (n = 12) and subjected to the airborne-particle abrasion with SiC with various pressure and grit size parameters. After treatment, the specimens were rinsed, dried, fused to dental ceramics, and examined for their shear strength using the Zwick/Roell Z020 machine. The results were statistically analysed using the ANOVA analysis of variance (α = 0.05). The highest metal-ceramic joint strength was obtained for abrasive blasting with 110 and 250 µm SiC grit at a pressure of 400 kPa. This relationship was also observed after the joint was subjected to thermal loads (5000 thermocycles). Additionally, thermal loads did not significantly reduce the joint’s strength compared with non-loaded joints. For small SiC abrasive grit sizes (50 µm) under pressure 400 kPa, the treatment pressure had a significant effect on the strength of the joint (p < 0.05). For larger particle sizes, the pressure had no effect. After abrasive blasting using SiC, the Ni-Cr metal-ceramic joint retained its properties, even under thermal load, ensuring the joint properties’ stability during use.     

Influence of the AlSi7Mg0.6 Aluminium Alloy Powder Reuse on the Quality and Mechanical Properties of LPBF Samples

Additive manufacturing (AM) is dynamically developing and finding applications in different industries. The quality of input material is a part of the process and of the final product quality. That is why understanding the influence of powder reuse on the properties of bulk specimens is crucial for ensuring the repeatable AM process chain. The presented study investigated the possibility of continuous reuse of AlSi7Mg0.6 powder in the laser powder bed fusion process (LPBF). To date, there is no study of AlSi7Mg0.6 powder reuse in the LPBF process to be found in the literature. This study aims to respond to this gap. The five batches of AlSi7Mg0.6 powder and five bulk LPBF samples series were characterised using different techniques. The following characteristics of powders were analysed: the powder size distribution (PSD), the morphology (scanning electron microscopy—SEM), the flowability (rotating drum analysis), and laser light absorption (spectrophotometry). Bulk samples were characterised for microstructure (SEM), chemical composition (X-ray fluorescence spectrometry—XRF), porosity (computed tomography—CT) and mechanical properties (tensile, hardness). The powder was reused in subsequent processes without adding (recycling/rejuvenation) virgin powder (collective ageing powder reuse strategy). All tested powders (powders P0–P4) and bulk samples (series S0–S3) show repeatable properties, with changes observed within error limits. Samples manufactured within the fifth reuse cycle (series S4) showed some mean value changes of measured characteristics indicating initial degradation. However, these changes also mostly fit within error limits. Therefore, the collective ageing powder reuse strategy is considered to give repeatable LPBF process results and is recommended for the AlSi7Mg0.6 alloy within at least five consecutive LPBF processes.     

Influence Mechanism of Ageing Parameters of Cu-Cr-Zr Alloy on Its Structure and Properties

The Cu-1.0% Cr-0.1% Zr alloy in a solid solution state was investigated by ageing treatments at different temperatures and holding times. The structure and performance were characterized and tested by using X-ray diffraction (XRD), a transmission electron microscope (TEM), a universal material testing machine, and an eddy conductivity detector. The influence laws of ageing temperature and the holding time on the structures and properties of the Cu-Cr-Zr alloy were analyzed. Results demonstrated that, with the increase in ageing temperature and holding time, the percentage and size of the Cr precipitated phase increased, and the dislocation density decreased. The tensile strength first increased to the peak value and then decreased. The electrical conductivity increased and the amplitude decreased. The tensile strength of the alloy reached the peak (359 ± 2 MPa) after ageing at 450 °C for 60 min, and the electrical conductivity was 91.9 ± 0.7% IACS. In addition, in the ageing precipitation process, the chromium precipitated phase had face-centered cubic structure (FCC) and body-centered cubic structure (BCC) structures, and the FCC Cr phase can be transformed into a BCC Cr phase. FCC Cr, BCC Cr, and Cu₃Zr precipitation phases maintained different orientation relationships with the Cu substrate.     

Influence of Sulfate-Reducing Bacteria on the Corrosion Residual Strength of an AZ91D Magnesium Alloy

In this paper, the corrosion residual strength of the AZ91D magnesium alloy in the presence of sulfate-reducing bacteria is studied. In the experiments, the chemical composition of corrosion film was analyzed by a scanning electron microscope with energy dispersive X-ray spectroscopy. In addition, a series of instruments, such as scanning electronic microscope, pH-meter and an AG-10TA materials test machine, were applied to test and record the morphology of the corrosion product, fracture texture and mechanical properties of the AZ91D magnesium alloy. The experiments show that the sulfate-reducing bacteria (SRB) play an important role in the corrosion process of the AZ91D magnesium alloy. Pitting corrosion was enhanced by sulfate-reducing bacteria. Corrosion pits are important defects that could lead to a significant stress concentration in the tensile process. As a result, sulfate-reducing bacteria influence the corrosion residual strength of the AZ91D magnesium alloy by accelerating pitting corrosion.     

Physicochemical Properties of Dentine Subjected to Microabrasive Blasting and Its Influence on Bonding to Self-Adhesive Prosthetic Cement in Shear Bond Strength Test: An In Vitro Study

The aim of this in vitro study was to assess the influence of microabrasive blasting on the physicochemical properties of dentine and shear bond strength (SBS) of self-adhesive resin cement (Maxcem Elite, Kerr, Orange, CA, USA) bonded to the dentine surface. Ninety cylindrical specimens with exposed dentine of human teeth were prepared and divided into three randomized, parallel sample sets A, B, and C. Groups B and C were subjected to abrasive blasting using a micro-sandblasting device (Microetcher IIa, Danville Materials, Carlsbad, CA, USA) with two gradations of Al₂O₃ abrasives (Group B, abrasion with a gradation of 50 μm; group C, abrasion with a gradation of 27 μm). SEM imaging, profilometry, chemical composition analysis, contact angle measurements, surface free energy, and SBS tests were performed. The resulting data were statistically analyzed using the Statistica software (ver. 13.3, Tibco Software Inc., Palo Alto, CA, USA). Microabrasive blasting caused changes in surface topography, structural features, and the connection strength between the dentin surface and self-adhesive prosthetic cement. Air microabrasion through the multifactorial positive reorganization of the treated surface of dentine is recommended as a pretreatment method in fixed prosthodontics adhesive cementation protocols.