Predicting the Adhesive Layer Thickness in Hybrid Joints Involving Pre-Tensioned Bolts

Area of Science:

• Materials Science
• Mechanical Engineering
• Manufacturing Processes

Background:

• Most research on hybrid joints focuses on cured properties.
• Hybrid joints (adhesive + bolts) offer superior performance over single methods.
• Nonuniform adhesive thickness during manufacturing impacts load capacity predictions.

Purpose of the Study:

• To investigate the manufacturing process of uncured hybrid joints.
• To precisely measure adhesive layer thickness distribution.
• To validate numerical predictions of adhesive flow using experimental data.

Main Methods:

• Experimental measurements of adhesive layer thickness for three adhesives.
• Computational Fluid Dynamics (CFD) modeling of adhesive flow and substrate interaction.
• Comparison of experimental thickness data with CFD predictions.

Main Results:

• CFD predictions showed good agreement with experimental adhesive thickness data.
• Relative differences between experimental and numerical average thickness ranged from 4.07% to 27.1%.
• Highest accuracy was achieved with an adhesive containing intact sand particles, preserving rheology.

Conclusions:

• The rheological behavior of adhesives significantly influences final adhesive layer thickness distribution.
• Accurate prediction of adhesive thickness is crucial for reliable load capacity assessment in hybrid joints.
• This research enhances the understanding of manufacturing processes for high-performance hybrid joints.