The mechanical performance of re-bonded and healed adhesive joints activable through induction heating systems

This work aims to study the healing potential properties of a reversible thermoplastic adhesive. The adhesive is activable by using induction heating systems that can induce thermal heat in the particles throughout the electromagnetic field so they can melt the adhesive for bonding or separation procedures. The healing procedure consists of damaging single lap joint (SLJ) specimens with quasi-static and fatigue tests and then using an inductor to generate an electromagnetic field able to heat the adhesive to its melting point in order to heal the damaged SLJ specimens. SLJ tests were performed on damaged and healed specimens to assess, respectively, the residual mechanical properties of the damaged specimens and the mechanical properties after healing. SLJ tests showed that the healing procedure can completely recover the joint stiffness of the damaged adhesive joints, a huge part of the maximum shear strength and the SLJ absorbed energy. This work shows also the possibility of re-bonding completely failed or separated SLJs by using the same procedure. The mechanical properties of SLJs after healing and re-bonding are compared to the SLJ compared on virgin specimens to assess the recovered mechanical properties

Experimental and Numerical Investigation of a Lattice Structure for Energy Absorption: Application to the Design of an Automotive Crash Absorber

In this work, an experimental and numerical analysis of a lattice structure for energy absorption was carried out. The goal was to identify the most influencing parameters of the unit cell on the crushing performances of the structure, thus guiding the design of energy absorbers. Two full factorial plans of compression tests on cubic specimens of carbon nylon produced by fused deposition modeling (FDM) were performed. The factors were the beam diameter and the number of unit cells. In the first factorial plan, the specimen volume is constant and the dimensions of the unit cell are varied, while the second factorial plan assumes a constant size of the unit cell and the volume changes in accordance with their number. The results showed that the specific energy absorption increases with the diameter of the beam and decreases with the size of the unit cell. Based on these results, a crash absorber for the segment C vehicle was designed and compared with the standard component of the vehicle made of steel. In addition to a mass reduction of 25%, the improved crushing performances of the lattice structure are shown by the very smooth force-displacement curve with limited peaks and valleys

Experimental assessment of the lean blow-off in a fully premixed annular combustor

The behaviour of the flame in an annular combustor with multiple bluff-body injectors with swirl was investigated to provide insights into lean blow-off (LBO) mechanisms when flames interact. Two different configurations, with 12 and 18 burners, and various bulk velocities and equivalence ratios were tested. Flame shape and main features were studied by means of 5 KHz OH$^*$ chemiluminescence imaging and the stability limits were identified and compiled into regime diagrams. As the equivalence ratio of the mixture was reduced the individual flames would first exhibit a transition from a stable ``W-shape" state to a stable ``V-shape" state before becoming unstable close to extinction. In the 18-burner configuration LBO was characterised by random detachment and re-stabilisation of the flame over multiple burners across the chamber, until complete lift-off. In the 12-burner configuration the flame anchors on a few burners in azimuthally symmetric locations, making the overall flame less prone to extinguish. Finally, the stability curves were computed using a correlation based on the Damkholer (Da) number and compared to single burner configurations. The beginning of the blow-off transient was found to be similar to the LBO condition for a single burner in the 12-burner setup, while the 18-burner configuration was less stable for all the conditions investigated. However, it was found that correlations based on single burner extinction data do not fully work for the extinction of interacting flames. The results provide insights into the blow-off of realistic gas turbine engines and can be used for validating models of such processes.EU Marie Skłodowska-Curie Grant Agreement No. 76599

An experimental-numerical methodology for the nondestructive assessment of the dynamic elastic properties of adhesives

In the last years, lightweight design has become a priority in many industrial sectors, like as the aerospace and the automotive industry, mainly due to the strict regulations in terms of gas emission and pollution. Together with lightweight materials, the use of adhesives to join different parts permits to significantly reduce the weight of mechanical assemblies. For a proper design of the joints, the mechanical properties of adhesives should be correctly experimentally assessed. However, the experimental assessment of the adhesive mechanical properties can be complex, since they can be hardly estimated from traditional experimental tests on lap joint or butt-joint specimens. The development of an experimental procedure for the assessment of the adhesive properties is therefore of interest. In the present paper, a methodology for the assessment of the dynamic elastic properties of adhesives, i.e., Young's modulus and the loss factor, is proposed. The procedure is based on the Impulse Excitation Technique and Finite Element Analyses (FEA). An automated routine has been written to assess the elastic properties by minimizing the difference between the frequency response obtained experimentally and through FEA. The proposed methodology has been experimentally validated to estimate the mechanical properties of an epoxy adhesive for automotive applications

Blow-off mechanisms of turbulent premixed bluff-body stabilised flames operated with vapourised kerosene fuels

The lean blow-off (LBO) behaviour of unconfined lean premixed blu -body stabilised flames with various fuels was investigated. Methane and vapourised ethanol, heptane, Jet-A1, and an alternative alcohol-derived kerosene (Gevo) were used. OH* chemiluminescence (5 kHz), OH- and Fuel-PLIF (5 kHz), and CH2O-PLIF (10 Hz) were deployed. For all fuels, as the flame approached LBO fragmentation was observed downstream, the two sides of the flame merged at the axis, pockets of OH and CH2O were found in the recirculation zone (RZ), and eventually the individual fragments extinguished. The CH2O seemed to enter into the RZ from downstream early in the LBO process, with reactants following suit at times closer to LBO. During LBO, the integrated OH* signal decreased slowly to zero and the duration of this transition was 25 (d=UBO) in the methane and ethanol flames and 60 (d=UBO) in flames operated with heptane and the two kerosenes (where d is the blu -body diameter and UBO the LBO velocity). This large di erence could be due to re-ignitions of partially-quenched fluid inside the RZ during the LBO event. Additionally, for the same bulk velocity, the kerosene flames blow-o at higher equivalence ratios than the single-component fuelled flames, which is possibly due to the higher Lewis number and lower extinction strain rates of these fuels. The results suggest that the blow-o mechanism is qualitatively similar for each of the fuels; however, the complex chemistry associated with heavy hydrocarbons appears to result in a prolonged LBO event.Cambridge Trust

Dynamic behaviour of polyolefin thermoplastic hot melt adhesive under impact loading conditions

Dynamic behavior of polyolefin thermoplastic hot melt adhesive under impact loading conditions R. Ciardiello1, A. Tridello1, G. Belingardi1, L. Goglio1. 1 Politecnico di Torino, Department of Mechanical and Aerospace Engineering, Torino, 10129, IT. The mechanical behaviour of adhesive joints under impact loadings is an active area of research due to significant industrial interests. Furthermore, the absence of a unique adopted standard for the study of bonded joints under impact loading increases the academic interests for this topic [1]. In this work, the static and the dynamic response of adhesive joints, bonded with a polyolefin hot-melt adhesive (HMA), were investigated by means of Single Lap Joint (SLJ) tests. The adhesive studied in this work is used in automotive application for bonding plastic internal and external plastic components [2], such as plastic bumpers that can be subjected to impacts during its life. The mechanical and thermal properties of this adhesive are presented in [3]. The main aim of this study is to test standard specimens, SLJ, under dynamic impacts with the use of a modified Charpy pendulum in order to compare the differences between static and dynamic behaviour. The substrate used in this activity are made of a polypropylene copolymer with 10% in weight of talc. Figure 1 shows the testing machine with the clamping system of the specimen. These special fixtures were designed by Goglio et al. [4] with the aim to apply a dynamic load on the tested SLJ. The specimen is fixed to the hammer at the front end, as shown in the right part of Figure 1; the back end is connected to a transverse tail, which hits the two stoppers fixed on the pendulum base, shown in the red circle of Figure 1. The fixtures hold the specimen during the fall of the hammer and transmit the load. A tail in aluminium alloy with T cross section was used, in order to guarantee a high stiffness during the impact, without adding excessive inertia to the system. The system is able to perform dynamic tests for SLJ specimens up to 3.75 m/s. Figure 1: Charpy pendulum used for the experimental tests. Mechanical tests show that there is a clear influence of the load rate on force-displacement diagram and on the maximum force for the tested adhesive. Figure 2 illustrates the differences between a representative curve of quasi-static test and dynamic tests with two different velocities. Figure 2: Force vs linear displacement: comparison between quasi-static and dynamic tests. Figure 3 shows the average values of the peak force and absorbed energies. This Figure illustrates that the velocity increase leads to an increase of the maximum force while the adsorbed energy significantly decreases by comparing quasi-static and dynamic tests. Figure 3: Peak loads and absorbed energy of the quasi-static and dynamic tests. Finally, the fracture surfaces of the SLJ specimens were assessed by means of visual inspection. This analysis showed that the joint separation in the quasi-static tests is mostly cohesive, whereas it becomes completely adhesive in dynamic tests. [1] J.J.M. Machado, E.A.S. Marques and L.F.M. da Silva, J. Adhes., (2017). https://doi.org/10.1080/00218464.2017.1282349. [2] G. Belingardi, V. Brunella, B. Martorana and R. Ciardiello, in Adhesives applications and properties, Cap.13, p.341, A. Rudawska Ed. (INTECH, Rijeca, 2016). [3] E. Koricho, E. Verna, G. Belingardi, B. Martorana, and V. Brunella, Int. J. Adhes. Adhes. 68, 169–181 (2016). [4] L. Goglio and M. Rossetto, in Proceedings of ESDA2006 8th Biennial ASME Conference on Engineering Systems Design and Analysis, 637-643 (2006)

Single-lap joints of similar and dissimilar adherends bonded with a polyurethane adhesive used in the automotive industry

The mechanical performances of single-lap joints between similar and dissimilar adherends bonded with a bi-component polyurethane adhesive have been studied in the present work. The substrate materials include both carbon fibre reinforced composite material (CRFP) and painted metal substrates (PMS). The following substrate combinations were tested: CFRP/CFRP, PMS/PMS, and CFRP/PMS. Two adhesive overlaps, 12 mm and 24 mm, with a fixed thickness were studied to assess the mechanical behaviour of the adhesive joints. The experimental results have been used to construct a finite element model of the single lap joint tests. The objective is to determine the material cohesive properties, in particular the maximum shear stress and the corresponding energy release rate, of the adhesive layer for each retained combination of substrates. An optimization scheme based on transient nonlinear finite element analysis has been here considered, where cohesive parameters of the adhesive layer are handled as design variables. Material parameters are firstly identified for the 12 mm overlap, minimizing the discrepancy between the experimental and numerical force-displacement curves. Then, to validate the obtained properties, results of the 24 mm overlap single lap joint tests are used. The comparison between the experimental and numerical results shows a very good agreemen

Epoxy and Bio-Based Epoxy Carbon Fiber Twill Composites: Comparison of the Quasi-Static Properties

In recent years, interest in sustainability has significantly increased in many industrial sectors. Sustainability can be achieved with both lightweight design and eco-friendly manufacturing processes. For example, concerns on the use of thermoset composite materials, with a lightweight design and a high specific strength, have arisen, since thermoset resins are not fully recyclable and are mainly petrol based. A possible solution to this issue is the replacement of the thermoset matrix with a recyclable or renewable matrix, such as bio-based resin. However, the mechanical properties of composites made with bio-based resin should be carefully experimentally assessed to guarantee a safe design and the structural integrity of the components. In this work, the quasi-static mechanical properties of composite specimens (eight layers of carbon fiber fabric) made with commercially available epoxy and a bio-based epoxy resins (31% bio content) are compared. Tensile tests on the investigated resins and tensile, compression, shear and flexural tests have been carried out on composite laminates manufactured with the two investigated resins. A finite element model has been calibrated in the LS-Dyna environment using the experimentally assessed mechanical properties. The experimental results have proven that the two composites showed similar quasi-static properties, proving that bio-based composite materials can be reliably employed as a substitute for epoxy resins without affecting the structural integrity of the component but lowering their carbon footprint

experimental investigation on adhesively bonded u shaped metallic joints using the arcan test

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