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Strength prediction of bonded joints remains a challenging task made even further complicated for hybrid joints in which adhesive is supplemented by mechanical fasteners. The present paper complements a series of experimental investigations on hybrid joints combining adhesive bonding with pre-tensioned bolts on galvanised and coated steel substrates, and considering two adhesives. The paper starts with modelling the strength of the bonded connection under the simultaneous action of tensile and compressive normal stresses, and shear. It then presents how these data are moulded into appropriate failure criteria and used the latter as input data for a subsequent full probabilistic finite element analysis. Following the paths of Weibull and subsequent researchers, joint capacity is predicted with reasonable accuracy for a dozen different combinations of substrates, adhesive, and pre-tension level – for which, on average, an accuracy slightly below 10% has been achieved. The results deliver meaningful insights into the subtle relationship between adhesive bonding, mechanical fastening, failure criteria, and resulting predictions methods. [ABSTRACT FROM AUTHOR]

Dimensioning adhesively bonded joints remains a challenging task. Their diversity in geometry and material (including combinations thereof), characteristic stress peaks, scatter and brittleness are aspects few practitioners are prepared to handle for dimensioning purposes. As developed in the first part of this two-part paper, direct stress based methods, despite diverse fudging techniques, proved to be unsuitable. This left the field open for fracture mechanics, which, however, departed very much from the engineering reality leading to only lukewarm acceptance from practitioners. Almost unnoticed, probabilistic methods, much closer to classical mechanics, may offer an alternative. Based upon the presentation, in the first part of this series, of the concepts, the authors suggested an implementation in terms of design procedure. The second part of this two-part paper, is dedicated to the presentation of several examples, from available literature, of adhesively bonded joints involving a large variety of typologies (single and double-lap, tubular, and hybrid joints) and materials (fibre-reinforced polymers, steel, wood). The focus therein is set on practitioner oriented aspects, in particular on techniques for implementation. [ABSTRACT FROM AUTHOR]

Recent adhesive research starts to consider more process oriented problems, in addition to the classical static stress and strength related topics, thus shifting towards a more global view on adhesive bonding. This includes the consideration of adhesive flow during application and joining of the substrates with all the information about initial application pattern and the resulting adhesive distribution contained after joining. Since the surface condition plays a major role and various different pretreatments are commonly used to improve the strength and durability of bonded joints while modifying their surface structure, the question of whether this influences the dynamics of the squeeze flow – or not – is addressed in this paper. In particular the materials glass and steel in combination with two designated surface pretreatments (blasting and flame-treatment) as well as their respective untreated reference surface are considered. For validation purposes the surfaces were characterized by means of roughness R a and contact angle θ measurements, performed before and after the pretreatment, which resulted in a range of surface parameters for R a from almost 0 to 3.3 μ m and for θ from approximately 0 to 35°. However based on the measured force–displacement behaviour during the squeeze process no statistically significant difference regarding the dynamics of the adhesive flow could be observed between the untreated and pretreated surfaces for all investigated materials. [ABSTRACT FROM AUTHOR]

Current studies show great, but unutilized potential for mechanical optimization of adhesively bonded joints. There are different approaches, e. g. mixed adhesive joints; tapered adherends or joints with spew fillets, all of which try to redistribute the stress peaks, occurring at the ends of adhesive layer overlap, in favor to the load capacity. However, these investigations fail to take a general approach to find optimal geometric solutions to the problem of joining two materials by means of adhesive bonding. Instead the geometry is changed by predefined parameters such as tapering angles, spew fillet radii or the number of adhesives in mixed adhesive joints. To allow a non-parametric optimization, this paper proposes and investigates an extended bi-directional evolutionary structural optimization methodology based on a failure criterion to account for othotropic materials, which are often used in the context of bonding. The optimized joint geometry, generated by the proposed algorithm, resulted in a fairly constant distribution of elemental failure probability compared to the non-optimized state, thus eliminating underutilized spots of material and increasing the efficiency of the connection. Furthermore the influence of different parameters such as the overlap-length to adherend thickness ratio; the stiffness between adherend and adhesive as well as the adherend degree of orthotropy were investigated for optimal joint geometry. [ABSTRACT FROM AUTHOR]

This study examines grouted joints for offshore wind turbine systems, where gaps between steel pipes are filled with grout, relying on adhesion, friction and compression struts formed by shear keys. Concerns about the limited load carrying capacity of large diameter grouted joints in offshore structures have prompted investigation. Whilst adhesive bonds are recognized for load transfer in structural steel, the complete replacement of grouting with bonding alone is proving impractical for large gaps in offshore structures, posing challenges in terms of cost and handling. To address these challenges, the study presents an innovative hybrid grouted joint for steel structures that combines grout and adhesive layers. This novel approach replaces traditional large shear keys with distributed micro-shear keys — small granules embedded in the grout material. Under axial loading, the hybrid joint demonstrates robust performance, with a maximum nominal shear stress on the inner pipe of 30.1 MPa and consistent load capacity across tests. Average shear strength is in line with, and occasionally exceeds, expectations. Notably, the hybrid joint shows resilience in different configurations and maintains a low coefficient of variation of 5.5%, indicating consistent performance. When the influence of the adhesive material on the hybrid joint is examined, the effect on the joint stiffness is minimal, despite variations in adhesive stiffness. Sikadur 370, which has a higher modulus of elasticity than DuploTEC, shows similar deformation curves in the elastic region, emphasizing the robustness of the joint. Differences in the maximum loads are attributed to the thickness of the adhesive layer and the lower modulus of DuploTEC, resulting in different shear strengths. The proposed hybrid joint offers a promising solution to improve the performance of conventional grouts and adhesives in offshore structures. The study also formulates a failure criterion, performs numerical stress analysis, and models the effect of geometric dimensions, eccentricity, and misalignment on load capacity. The methodology's accuracy in predicting load capacity, supported by numerical analysis and large-scale joint simulations, contributes to a comprehensive understanding of hybrid joint performance in engineering applications. [ABSTRACT FROM AUTHOR]

This last paper of a series of three concludes the analysis of a series of adhesively bonded tube-in-tube (TiT) joints composed of glass-fibre reinforced polymers (G-FRP) for which induction heating with Curie-particles (CP) was used to accelerate curing. It focuses on the prediction of their load capacity using a probabilistic method (PM). First, the G-FRP material was characterised with regard to transverse (tensile) and shear stresses, which allowed to determine a valid failure criterion, including the related statistical description subsequently required for the PM. Then, finite element analysis (FEA) was used to determine the stresses within the TiTs, for not only a perfect geometry, but also considering a series of possible geometrical imperfections (offset and misalignment of the centrelines, and ovalisation) with three degrees of severity. The influence of aforesaid imperfections on stresses was determined, and discussed. Based thereupon, load capacity was numerically determined, compared to the experimental values, and the influence of imperfections highlighted. Predicted joint capacities agreed well with the experimental ones. The influence of centreline offset and ovalisation was found to be of minor importance, if compared to that of the misalignment. By an extension of the procedure, scattering of the experimental data was also predicted in form of upper and lower quantiles, which also agreed well. [ABSTRACT FROM AUTHOR]