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Influence of raw material surface roughening on the lap shearing strength and failure behavior of adhesively bonded aluminum joints

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Abstract

Surface roughening of the substrates before bonding plays a significant effect on improving the mechanical performance of the adhesively bonded joints, which are prevalently used for light-weighting vehicle bodies. In this study, the influence of surface roughening on the lap shearing strength and failure behavior of adhesively bonded aluminum sheet joints was investigated. Sandpaper grinding was employed for surface roughening; methods such as tensile testing and microstructure observation were employed for evaluating the performance of the joints. The results showed that the lap shearing strength of adhesively bonded joints increased and then decreased with the surface roughness of the aluminum substrate. The maximum shearing strength of the joint bonded with grinded substrates was 30.4 MPa which was improved by 57.5% compared to that produced with un-grinded substrates. However, over-roughening is harmful. When the surface roughness was too large, the failure mode of the joint turned from the mixed failure mode to the interfacial failure mode, which decreased the strength of the joints. Related mechanisms were demonstrated. When the substrate surface was coarsened, the bonding area and the wettability of the adhesive on the surface were both increased, which promoted the beneficial mechanical interlock effect between the adhesive and the substrate. However, when the substrate surface was over-roughened, defects such as voids and insufficient infiltrating of the adhesive were induced, which apparently increased the proportion of the interfacial failure area.

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Funding

This work was funded by the National Natural Science Foundation of China [grant numbers 51975201, U20A20275], the Foundation of Zhejiang Province Key Laboratory of Automobile Safety [grant number GL/20-002X], and the Natural Science Foundation of Hunan Province, China [grant number 2021JJ40096].

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Authors and Affiliations

  1. State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, College of Mechanical and Vehicle Engineering, Hunan University, Changsha, Hunan, 410082, China

    Jianpeng Liu, Hong He, Zhigang Xue, Congchang Xu & Luoxing Li

  2. Zhejiang Key Laboratory of Automobile Safety Technology, Geely Automobile Research Institute (Ningbo) Co., Ltd, Ningbo, Zhejiang, 315336, People’s Republic of China

    Wei Wang

  3. China North Advanced Technology Generalization Institute, Bei**g, 100089, China

    Yong Yan

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  1. Jianpeng Liu
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  4. Hong He
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  5. Zhigang Xue
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Contributions

Jianpeng Liu: investigation, methodology, writing – original draft preparation. Wei Wang and Yong Yan: experiment preparation. Zhigang Xue and Congchang Xu: testing and data collecting. Luoxing Li: writing – reviewing and editing. Hong He: methodology, revision, writing – reviewing and editing.

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Correspondence to Hong He.

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Liu, J., Wang, W., Yan, Y. et al. Influence of raw material surface roughening on the lap shearing strength and failure behavior of adhesively bonded aluminum joints. Int J Adv Manuf Technol 122, 327–342 (2022). https://doi.org/10.1007/s00170-022-09590-6

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