Linear vs nonlinear ultrasonic testing of kissing bonds in adhesive joints.

Kissing bonds in adhesive joints are precursors to damage and failure in materials and components used in safety-critical industries. They are zero-volume, low-contrast contact defects widely regarded as "invisible" in conventional ultrasonic testing. In this study, the recognition of the kissing bonds is examined in automotive industry-relevant aluminum lap-joints with standard bonding procedures using epoxy- and silicone-based adhesives. The protocol to simulate kissing bonds comprised customary surface contaminants PTFE oil and PTFE spray. Preliminary destructive tests revealed brittle fracture of the bonds with typical single-peak stress-strain curves indicating ultimate strength reduction due to adding contaminants. The curves are analyzed by using nonlinear stress-strain relation with the higher-order terms containing the higher-order nonlinearity parameters. It is shown that the lower-strength bonds manifest a high nonlinearity while the high-strength contacts are candidates for a low nonlinearity. Based on that, the nonlinear approach is set side by side with linear ultrasonic testing for experimental locating of the kissing bonds fabricated in the adhesive lap-joints. The sensitivity of the linear ultrasound is shown to be adequate to detect only a substantial bonding force reduction caused by the irregular interface defects in adhesives, while a minor contact softening due to kissing bonds remains undistinguishable. On the contrary, the probing of the kissing bonds vibration with nonlinear laser vibrometry reveals dramatic growth of the higher harmonic amplitudes and thus validates highly-sensitive detectabilty of these troublesome defects.

Electrochemical Behavior and Interfacial Delamination of a Polymer-Coated Galvanized Steel System in Acid Media.

The degradation behavior of polymer coatings is essential for their protective performance under various corrosive environments. Herein, electrochemical impedance spectroscopy (EIS) is employed to study the corrosion behavior and interfacial delamination of a polymer-coated metal system exposed to 0.1, 0.5, and 1 mol/L H2SO4 solutions at 50 °C. The electrochemical impedance spectra are analyzed using different equivalent circuits to derive the time dependence of the parameters of the coating, delaminated area, and interfacial processes. The phase angle at 10 Hz (θ10 Hz) is not appropriate in the case of higher delamination area ratio α, while θ10 kHz provides a rapid approach to evaluate the degradation of polymer-coated metal systems. The frequency of the phase angle at -45° (f -45°) leads to a wrong evaluation for higher α and can be no longer viewed as the breakpoint frequency. The frequency f p obtained by the changing rate of phase angle (CRPA) method is proposed to monitor the coating degradation and determine the breakpoint frequency with the consideration of dispersive number n. The frequency f EIS derived from fitting EIS spectra shows a good agreement with f p, which can contribute to clarify the evolution in the process of degradation.

Linear Elastic FE-Analysis of Porous, Laser Welded, Heat Treatable, Aluminium High Pressure Die Castings Based on X-Ray Computed Tomography Data.

The welding of aluminium high pressure die castings is a well known and broadly investigated challenge in various fields of industry and research. Prior research in this specific field mainly focused on the optimisation of the welding and the casting process and on the cause of the frequently occurring porosity and incomplete fusion phenomena, whereas the impacts of these defects have hardly been addressed. Therefore, the underlying study presents the investigation of weldments in EN AC-AlSi10MnMg high pressure aluminium die castings by linear elastic finite element analysis based on X-ray computed tomography as a novel approach. Hereby, four laser weldments with differing surfaces and pore contents were investigated by X-ray computed tomography and tensile testing. Based on the voxel datasets of the porous weldments, triangular finite element meshes were generated and a numerical finite element analysis was conducted. Good agreement of the stress-strain curves between the simulations and the experiments was achieved.

Influence of Restraint Conditions on Welding Residual Stresses in H-Type Cracking Test Specimens.

From the viewpoint of mechanics, weld cracking tends to occur if the induced tensile stress surpasses a certain value for the particular materials and the welding processes. Welding residual stresses (WRS) can be profoundly affected by the restraint conditions of the welded structures. For estimating the tendency of weld cracking, the small-scale H-type slit joints have been widely used for cracking tests. However, it is still hard to decide whether the real large-scale component can also be welded without cracking even though the tested weld cracking specimens on the laboratory scale can be welded without cracking. In this study, the intensity of restraint which quantitatively indicates how much a joint is restrained is used. The influence of restraint condition (intensity of restraint) on WRS is systematically investigated using both the numerical simulation and the experimental method. The achievement obtained in the current work is very beneficial to design effective H-type self-restrained cracking test specimens for evaluating the sensitivity of the material and the welding procedures for weld cracking in the real large-scale components.

Composite Bonding Pre-Treatment with Laser Radiation of 3 µm Wavelength: Comparison with Conventional Laser Sources.

To use the full potential of composite parts, e.g., to reduce the structural weight of cars or airplanes, a greater focus is needed on the joining technology. Adhesive bonding is considered favorable, superior joining technology for these parts. Unfortunately, to provide a structural and durable bond, a surface pre-treatment is necessary. Due to its high integration potential in industrial process chains, laser radiation can be a very efficient tool for this purpose. Within the BMBF-funded (German Federal Ministry of Education and Research) project GEWOL, a laser source that emits radiation at 3 µm wavelength (which shows significant advantages in theory) was developed for a sensitive laser-based bonding pre-treatment. Within the presented study, the developed laser source was compared with conventional laser sources emitting radiation at 355 nm, 1064 nm, and 10,600 nm in terms of application for a composite bonding pre-treatment. With the different laser sources, composites were treated, analytically tested, subsequently bonded, and mechanically tested to determine the bonding ability of the treated specimens. The results show a sensitive treatment of the surface with the developed laser source, which resulted in a very effective cleaning, high bonding strengths (over 32 MPa), and a good effectiveness compared with the conventional laser sources.