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Presently, the materials used in light combat aircraft structures are aluminium alloys and composites. These structures are joined together through riveted joints. The weight of these rivets for the entire aircraft is nearly one ton. In addition to weight, the riveted connection requires a lot of tools, equipments, fixtures and manpower, which makes it an expensive and time-consuming process. Moreover, Al alloy is also welded using tungsten inert gas (TIG) welding process by proper control of process parameters. This process has limitations such as porosity, alloy segregation and hot cracking. To overcome the above limitations, an alternative technology is required. One such technology is friction stir welding (FSW), which can be successfully applied for welding of aluminium alloy in LCA structures. Therefore, this paper aims to compare the load carrying capabilities of FSW joints with TIG welded and riveted joints.

FSW joints and TIG welded joints were fabricated using optimized process parameters, followed by riveted joints using standard shop floor practice in the butt and lap joint configurations.

The load-carrying capabilities of FSW joints are superior than those of other joints. FSW joints exhibited 75 per cent higher load-carrying capability compared to the riveted joints and TIG-welded joints.

From this investigation, it is inferred that the FSW joint is suitable for the replacement of riveted joints in LCA and TIG-welded joints.

Friction stir butt joints exhibited 75 per cent higher load-carrying capability than riveted butt joints. Friction stir welded lap joints showed 70 per cent higher load-carrying capability than the riveted lap joints. Friction stir butt joints yielded 41 per cent higher breaking load capabilities than the TIG-welded butt joints. Moreover, Friction stir lap weld joints have 57 per cent more load-carrying capabilities than the TIG-welded lap joints.

The purpose of this paper is to evaluate the mechanical properties of nano‐silver paste sintered lap shear structures and to discuss the effects of loading rate and ambient temperature on shear strength and fracture mechanism.

Single lap shear joints with an area of 2 mm² and thickness of 50 μm were fabricated by joining two copper substrates with nano‐silver paste. The lap shear tests were carried out under strain control mode on a micro uniaxial fatigue testing system with four loading rates and temperatures. The fracture sections were analyzed by SEM observation to determine the effect of temperature on the fracture mechanism.

Results from the study highlighted that the shear strain rate and temperature can have a significant impact on the shear behaviour of nano‐silver paste sintered lap shear joints. The shear strength increased with shear strain rate, but decreased with increasing ambient temperature. The lap shear joints displayed excellent ductility at higher temperatures due to the grain plastic flow.

So far, the investigation of the mechanical behaviour of low‐temperature sintered nano‐silver paste was restricted to a film form. No work had been done on nano‐silver paste connected structures. The findings presented in this paper give a basic understanding of the mechanical properties of nano‐silver sintered joints when sheared under different loading rates and temperatures.

The purpose of this paper is to evaluate and exploit the combination of additive manufacturing polymeric technology and structural adhesives. The main advantage is to expand the maximum dimension of the 3D printed parts, which is typically limited, by joining the parts with structural adhesive, without losing strength and stiffness and keeping the major asset of polymeric 3 D printing: freedom of shape of the system and low cost of parts.

The materials used in the paper are the following. The adhesive considered is a commercial inexpensive acrylic, quite similar to superglue, applicable with almost no surface preparation and fast curing, as time constraint is one of the key problems that affects industrial adhesive applications. The 3D printed parts were in acrylonitrile butadiene styrene (ABS), obtained with a Fortus 250mc FDM machine, from Stratasys. The work first compares flat overlap joint with joints designed to permit mechanical interlocking of the adherends and then to a monolithic component with the same geometry. Single lap, joggle lap and double lap joints are the configurations experimentally characterized following a design of experiment approach.

The results show a failure in the substrate, due to the low strength of the polymeric adherends for the first batch of typical bonded configurations, single lap, joggle lap and double lap. The central bonded area, with an increased global thickness, never does fail, and the adhesive is able to transfer the load both with and without mechanical interlocking. An additional set of scarf joints was also tested to promote adhesive failure as well as to retrieve the adhesive strength in this application. The results shows that bonding of polymeric AM parts is able to express its full potential compared with a monolithic solution even though the joint fails prematurely in the adherend due to the bending stresses and the notches present in the lap joints.

Because of the 3D printed polymeric material adopted, the results may be generalized only when the elastic properties of the adherends and of the adhesive are similar, so it is not possible to extend the findings of the work to metallic additive manufactured components.

The paper shows that the adhesives are feasible way to expand the potentiality of 3 D printed equipment to obtain larger parts with equivalent mechanical properties. The paper also shows that the scarf joint, which fails in the adhesive first, can be used to extract information about the adhesive strength, useful for the designers which have to combine adhesive and additive manufactured polymeric parts.

To the best of the researchers’ knowledge, there are scarce quantitative information in technical literature about the performance of additive manufactured parts in combination with structural adhesives and this work provides an insight on this interesting subject. This manuscript provides a feasible way of using rapid prototyping techniques in combination with adhesive bonding to fully exploit the additive manufacturing capability and to create large and cost-effective 3 D printed parts.

To provide a basis for making assessment of the safety of adhesively bonded joints after they have been de‐painted by a dry abrasive method or a wet chemical method.

Stress analysis by a finite element method has been conducted for metal/composite and composite/composite joints in a single lap configuration. The effects of degradation of composite and adhesive, separately or combined, on the stresses in the adhesive layer bonding the two components are studied. Effects of wet and dry conditions of de‐painting are included in the study. It is assumed that in the composite these conditions affect only the laminae close to the surface from which the paint coating is removed.

The locations and values of the maximum peel and shear stresses in the adhesive are determined for both joints under different assumed conditions of degradation caused by de‐painting.

Experimental data indicating the extent of surface damage caused by de‐painting is not available.

Extensive literature study did not show any investigation of composite surface damage and adhesive property degradation on integrity of adhesively bonded joints. Results reported here will be of use in assessing effects of de‐painting on the structural performance of adhesively bonded joints.

Fibre reinforced polymer composites (FRPs) are finding increasing usage in many industrial sectors. Adhesive bonding is often the most attractive joining technique for these materials in terms of structural efficiency and cost of manufacture. However, concerns regarding the lack of reliable design methods, the long term ageing behaviour and the difficulties in non‐destructive evaluation and repair of bonded joints has led to a reluctance to use adhesives in primary structures. DERA has been involved in the assessment of adhesive bonding for joining FRPs for many years. This paper focuses on investigations at DERA into the effects that environment and fatigue loading have on the performance of bonded composite joints, and briefly reviews current approaches to strength and lifetime prediction. It is seen that adhesively bonded composite joints can be significantly affected by the service environment, however, this is highly dependent on the joint type and materials involved.

The use of synthetic resins as adhesives for metals or other non‐porous materials, in which there is increasing interest for structural and production reasons, imposes certain restrictions on the components bonded and the type of joint used. In the following paper the general points applicable to adhesive joints are first considered. A large number of strength measurements on simple light alloy lap joints made with ‘Araldite’ by the Eidg. Materialprüfungs und Versuchsanstalt (E.M.P.A.) are used to analyse the manner in which the breaking load under tensile shear loading depends on the geometry of the test specimen. It can be shown that in this special case, which is however of importance in practice, there is an optimum utilization both of the adhesive and of the metal, whose yield point determines the choice of sheet thickness and overlap. The use of synthetic resins as adhesives for metals and other non‐porous materials opens up numerous new developments and possibilities in a whole range of industries. Although comparatively new it has already found many practical applications which steadily increase.

The purpose of this paper is to apply the novel instantaneous power flow balance (IPFB)-based identification strategy to a specific practical situation like nonlinear lap joints having single and double bolts. The paper also investigates the identification performance of the proposed power flow method over conventional acceleration-matching (AM) methods and other methods in the literature for nonlinear identification.

A parametric model of the joint assembly formulated using generic beam element is used for numerically simulating the experimental response under sinusoidal excitations. The proposed method uses the concept of substructure IPFB criteria, whereby the algebraic sum of power flow components within a substructure is equal to zero, for the formulation of an objective function. The joint parameter identification problem was treated as an inverse formulation by minimizing the objective function using the Particle Swarm Optimization (PSO) algorithm, with the unknown parameters as the optimization variables.

The errors associated with identified numerical results through the instantaneous power flow approach have been compared with the conventional AM method using the same model and are found to be more accurate. The outcome of the proposed method is also compared with other nonlinear time-domain structural identification (SI) methods from the literature to show the acceptability of the results.

In this paper, the concept of IPFB-based identification method was extended to a more specific practical application of nonlinear joints which is not reported in the literature. Identification studies were carried out for both single-bolted and double-bolted lap joints with noise-free and noise-contamination cases. In the current study, only the zone of interest (substructure) needs to be modelled, thus reducing computational complexity, and only interface sensors are required in this method. If the force application point is outside the substructure, there is no need to measure the forcing response also.

The purpose of this paper is to present a novel assembly spring-back model which takes surface contact conditions between sheet metal parts into consideration so that the assembly dimensions and variations can be more precisely predicted than existing assembly simulation models.

Because an assembly process is composed of four essential steps, i.e. locating, clamping, joining and tool releasing, the mechanistic models associated with these steps are developed in the paper. In particular, the surface contact between the weld flanges (in folding joint configuration) and the overlapping surfaces (in lap joint configurations) is included in the models. Sensitivity models are developed.

Two cases studies are presented, i.e. the cantilever beams assembly and the Z-plates assembly. More precise prediction results are shown.

The model developed in this paper is based upon analytical elastic beam theories. Therefore, the results and case studies are limited only to workpieces that can be approximately represented by beam geometries. However, the methods can be broadened to generic workpiece geometries by using finite element methods; thus, the developed method is highly valuable to a broad range of applications such as automotive body assembly and aerospace industries.

The novelty of this research lies in its inclusion of surface contact conditions in an assembly simulation model by using analytical beam mechanistic models to achieve more accurate assembly variation predictions.

This study aims to investigate the effect of opposing notches formed on the adherends on the tensile strength of an adhesively bonded single-lap joint.

Different notch geometries were constructed on adherends and evaluated by using the Taguchi method to obtain optimum notch geometry. Then finite element analysis was conducted considering optimum notch geometries by using the cohesive zone model. Lastly, finite element analysis results were validated experimentally.

Experimental and numerical studies revealed that notches formed on adherends increased the tensile strength of the joint. The failure load of the Type-III joint, where the highest increase was observed, increased by 15 per cent. In addition, it was found that the notch shape, length, depth and distance to the overlap area had significant effects on the failure load of the joint.

This study shows that higher joint strengths can be accomplished by using the same joint configuration by notching adherends.

Magnetic properties of step‐lap joints have been investigated experimentally on scale‐models of a three‐phase three‐leg transformer core. The influence of core induction, number of steps and overlapping length has been investigated.