Towards Reliable Adhesive Bonding: A Comprehensive Review of Mechanisms, Defects, and Design Considerations

Area of Science:

• Materials Science
• Engineering

Background:

• Adhesive bonding is a versatile joining method replacing traditional fasteners in various industries.
• Understanding adhesion mechanisms, adhesive types, and application criteria is crucial for effective use.

Purpose of the Study:

• To comprehensively review adhesive bonding, focusing on challenges, defects, and sustainability.
• To identify the need for unified frameworks in defect assessment and failure prediction.

Main Methods:

• Literature review of fundamental adhesion mechanisms and adhesive types.
• Analysis of factors affecting bond quality, including defects and surface preparation.
• Exploration of sustainability aspects like disassembly and recyclability.

Main Results:

• Identified common defects (kissing bonds, porosity, voids) impacting bond integrity.
• Highlighted challenges in assessing defect interactions and predicting failure due to complexity and data limitations.
• Emphasized the need for sustainable solutions in automotive and aerospace sectors.

Conclusions:

• A unified framework for defect interaction and failure prediction in adhesive joints is lacking.
• Multi-method detection, advanced modeling (debond-on-demand, bio-based adhesives), and defect correlation are essential.
• Future research should prioritize sustainable adhesive technologies to enhance reliability and support a circular economy.