Experimental and Numerical Study on Mechanical Properties of Z-pins Reinforced Composites Adhesively Bonded Single-Lap Joints

The mechanical properties of Z-pins reinforced composites adhesively bonded single-lap joints(SLJs)under un-directional tension loading are investigated by experimental and numerical methods.Three kinds of joint configurations,including SLJs with three/two rows of Z-pins and“I”array of Z-pins,are investigated by tension test.The failure modes and mechanism of reinforced joints with different Z-pins numbers and alignment are analyzed,and the comparison is performed for the failure strengths of no Z-pins and Z-pins reinforced joints.According to experimental results,failure modes of three kinds of joints are all mixed failure.It turns out that the Z-pins are pulled out ultimately.The strength of joints of more Z-pins at the end of the overlap area is relatively bigger for the joint of the same Z-pins numbers.The strength of joints with Z-pins compared with non Z-pins joints is growing at 16%.Finally,the three-dimensional distribution of interfacial stress in the lap zone of three kinds of Z-pins reinforced joints is simulated,and the numerical results are in good agreement with the experimental results.It is effective that the numerical calculation of stress analysis is verified.

Cyclic shear behavior of en-echelon joints under constant normal stiffness conditions

To reveal the mechanism of shear failure of en-echelon joints under cyclic loading,such as during earthquakes,we conducted a series of cyclic shear tests of en-echelon joints under constant normal stiffness(CNS)conditions.We analyzed the evolution of shear stress,normal stress,stress path,dilatancy characteristics,and friction coefficient and revealed the failure mechanisms of en-echelon joints at different angles.The results show that the cyclic shear behavior of the en-echelon joints is closely related to the joint angle,with the shear strength at a positive angle exceeding that at a negative angle during shear cycles.As the number of cycles increases,the shear strength decreases rapidly,and the difference between the varying angles gradually decreases.Dilation occurs in the early shear cycles(1 and 2),while contraction is the main feature in later cycles(310).The friction coefficient decreases with the number of cycles and exhibits a more significant sensitivity to joint angles than shear cycles.The joint angle determines the asperities on the rupture surfaces and the block size,and thus determines the subsequent shear failure mode(block crushing and asperity degradation).At positive angles,block size is more greater and asperities on the rupture surface are smaller than at nonpositive angles.Therefore,the cyclic shear behavior is controlled by block crushing at positive angles and asperity degradation at negative angles.

Shear behavior and off-fault damage of saw-cut smooth and tension-induced rough joints in granite

The damage of rock joints or fractures upon shear includes the surface damage occurring at the contact asperities and the damage beneath the shear surface within the host rock.The latter is commonly known as off-fault damage and has been much less investigated than the surface damage.The main contribution of this study is to compare the results of direct shear tests conducted on saw-cut planar joints and tension-induced rough granite joints under normal stresses ranging from 1 MPa to 50 MPa.The shear-induced off-fault damages are quantified and compared with the optical microscope observation.Our results clearly show that the planar joints slip stably under all the normal stresses except under 50 MPa,where some local fractures and regular stick-slip occur towards the end of the test.Both post-peak stress drop and stick-slip occur for all the rough joints.The residual shear strength envelopes for the rough joints and the peak shear strength envelope for the planar joints almost overlap.The root mean square(RMS)of asperity height for the rough joints decreases while it increases for the planar joint after shear,and a larger normal stress usually leads to a more significant decrease or increase in RMS.Besides,the extent of off-fault damage(or damage zone)increases with normal stress for both planar and rough joints,and it is restricted to a very thin layer with limited micro-cracks beneath the planar joint surface.In comparison,the thickness of the damage zone for the rough joints is about an order of magnitude larger than that of the planar joints,and the coalesced micro-cracks are generally inclined to the shear direction with acute angles.The findings obtained in this study contribute to a better understanding on the frictional behavior and damage characteristics of rock joints or fractures with different roughness.

Three‑dimensional numerical simulation of dynamic strength and failure mode of a rock mass with cross joints

To study the dynamic mechanical properties and failure characteristics of intersecting jointed rock masses with different joint distributions under confining pressure,considering the cross angleαand joint persistence ratioη,a numerical model of the biaxial Hopkinson bar test system was established using the finite element method–discrete-element model coupling method.The validity of the model was verified by comparing and analyzing it in conjunction with laboratory test results.Dynamics-static combined impact tests were conducted on specimens under various conditions to investigate the strength characteristics and patterns of crack initiation and expansion.The study revealed the predominant factors influencing intersecting joints with different angles and penetrations under impact loading.The results show that the peak stress of the specimens decreases first and then increases with the increase of the cross angle.Whenα<60°,regardless of the value ofη,the dynamic stress of the specimens is controlled by the main joint.Whenα≥60°,the peak stress borne by the specimens decreases with increasingη.Whenα<60°,the initiation and propagation of cracks in the cross-jointed specimens are mainly controlled by the main joint,and the final failure surface of the specimens is composed of the main joint and wing cracks.Whenα≥60°orη≥0.67,the secondary joint guides the expansion of the wing cracks,and multiple failure surfaces composed of main and secondary joints,wing cracks,and co-planar cracks are formed.Increasing lateral confinement significantly increases the dynamic peak stress able to be borne by the specimens.Under triaxial conditions,the degree of failure of the intersecting jointed specimens is much lower than that under uniaxial and biaxial conditions.

RB-DEM Modeling and Simulation of Non-Persisting Rough Open Joints Based on the IFS-Enhanced Method

When the geological environment of rock masses is disturbed,numerous non-persisting open joints can appear within it.It is crucial to investigate the effect of open joints on the mechanical properties of rock mass.However,it has been challenging to generate realistic open joints in traditional experimental tests and numerical simulations.This paper presents a novel solution to solve the problem.By utilizing the stochastic distribution of joints and an enhanced-fractal interpolation system(IFS)method,rough curves with any orientation can be generated.The Douglas-Peucker algorithm is then applied to simplify these curves by removing unnecessary points while preserving their fundamental shape.Subsequently,open joints are created by connecting points that move to both sides of rough curves based on the aperture distribution.Mesh modeling is performed to construct the final mesh model.Finally,the RB-DEM method is applied to transform the mesh model into a discrete element model containing geometric information about these open joints.Furthermore,this study explores the impacts of rough open joint orientation,aperture,and number on rock fracture mechanics.This method provides a realistic and effective approach for modeling and simulating these non-persisting open joints.

On the calibration of a shear stress criterion for rock joints to represent the full stress-strain profile

Conventional numerical solutions developed to describe the geomechanical behavior of rock interfaces subjected to differential load emphasize peak and residual shear strengths.The detailed analysis of preand post-peak shear stress-displacement behavior is central to various time-dependent and dynamic rock mechanic problems such as rockbursts and structural instabilities in highly stressed conditions.The complete stress-displacement surface(CSDS)model was developed to describe analytically the pre-and post-peak behavior of rock interfaces under differential loads.Original formulations of the CSDS model required extensive curve-fitting iterations which limited its practical applicability and transparent integration into engineering tools.The present work proposes modifications to the CSDS model aimed at developing a comprehensive and modern calibration protocol to describe the complete shear stressdisplacement behavior of rock interfaces under differential loads.The proposed update to the CSDS model incorporates the concept of mobilized shear strength to enhance the post-peak formulations.Barton’s concepts of joint roughness coefficient(JRC)and joint compressive strength(JCS)are incorporated to facilitate empirical estimations for peak shear stress and normal closure relations.Triaxial/uniaxial compression test and direct shear test results are used to validate the updated model and exemplify the proposed calibration method.The results illustrate that the revised model successfully predicts the post-peak and complete axial stressestrain and shear stressedisplacement curves for rock joints.

Effect of Hygrothermal Cycle Aging on the Mechanical Behavior of Single-lap Adhesive Bonded Joints

The aging behavior of single lap joints(SLJ) in hygrothermal cycles was investigated and compared by using a shearing strength test, Fourier transform infrared spectroscopy(FTIR), thermogravimetric analysis(TG/DTG), energy dispersive spectrometry(EDS) and scanning electronic microscopy(SEM). The temperature/relative humidity was set at 80 ℃/95% and –40 ℃/30% for 20 cycles, 40 cycles, and 60 cycles(one cycle was 12 hours), respectively. The experimental results show that hygrothermal aging significantly decreases the failure strength of adhesive joints. However, the failure displacement increases as the number of aging cycles increases. In addition, hygrothermal aging changes the failure mode of the adhesive joints from a cohesive fracture in un-aged adhesive layers to an interfacial failure of aged adhesive joints.

Effect of cold-working on corrosion induced damage in lug joints

Lug joints are preferred joineries for transferring heavy loads to parent components in aerospace vehicles.They experience corrosion due to environmental conditions,improper surface finishes and rubbing displacement between the pin and lug-hole.This causes damage of different sizes and shapes near the lug-hole.Stiffness degradation due to corrosion-induced damage is modelled as a through-pit at one of the identified critical locations through stress analysis.The effect of this pit on fatigue crack initiation life is estimated.Lug-hole is pre-stressed by cold-working and the benefits of inducing plastic wake on the intended performance of the lug joint during the damages due to corrosion are brought out and compared with non-cold-worked lug-hole.Numerical analysis is performed on this lug joint with pressfit.The results obtained highlight the benefits of cold-working and the methodology can be extended to damage growth and analyse the effect of surface treatments for better structural integrity of components of aerospace vehicles.

Microstructure and mechanical performance of AZ31/6061 lap joints welded by laser-TIG hybrid welding with Zn-Al alloy filler metal

A series of Zn-xAl(x=0-35 wt.%)alloy filler metals were designed to join AZ31 Mg alloy to 6061 Al alloy by laser-TIG hybrid welding.The effect of Al content on the wettability of filler metals,microstructure evolution and strength of joint was investigated.The results indicated that the strength of joints was improved with the increase of Al content in filler metals.When Zn-15Al filler was used,the ultimate fracture load reached the maximum of 1475.3 N/cm,which was increased by 28%than that with pure Zn filler.The reason is that the Al element acts as a"reaction depressant"in filler metal,which contributes to inhibiting the dissolution of Mg base metal and the Mg-Zn reaction.The addition of appropriate quantity of Al element promoted the precipitation of Al-rich solid solution instead of Zn solid solution.The MgZn_(2) IMCs have lower lattice mismatch with Al solid solution than Zn solid solution,thus the strength of joints is improved.However,the excessive addition of Al caused the formation of brittle Mg32(Al,Zn)49 ternary compounds,leading to the deterioration of joint performance.

Synthesis of organic-inorganic 3D-nanocontainers for smart corrosion protection of friction stir welded AZ31B magnesium alloy-titanium dissimilar joints

The joining of different light metals through friction stir welding(FSW)is gaining interest as a method to decrease weight and improve fuel efficiency.However,to ensure durability,these welded metals may require surface treatments to protect against corrosion or wear.This study presents a novel approach for the simultaneous delivery of two distinct corrosion inhibitors to Ti-Mg dissimilar PEO treated joints on demand.The research focuses on the synthesis,characterization,and application of cerium@polystyrene(Ce@PS)nanocontainers,which are loaded with 8-hydroxyquinoline(8-HQ)to enhance corrosion protection.The synthesis involves several key steps,including the formation of a cerium-based outer layer around polystyrene nanospheres,the selective removal of the polystyrene core to create a porous structure,and the subsequent loading of the 8-HQ inhibitor.Structural and compositional analyses,conducted using scanning transmission electron microscopy(STEM)and energy-dispersive X-ray spectroscopy(EDS),confirmed the successful incorporation of 8-HQ within the nanocontainers.Additionally,Fourier-transform infrared spectroscopy(FTIR)provided detailed information about the chemical composition of the organic materials throughout the synthesis process.Thermal decomposition analysis verified the successful fabrication and stability of the dual-shell nanocontainers.Corrosion tests on Ti-Mg joints treated with plasma electrolytic oxidation(PEO)coatings and loaded nanocontainers demonstrated sig-nificantly improved corrosion resistance compared to untreated joints.This research highlights the potential of dual-shell nanocontainers,containing both organic and inorganic inhibitors,to offer prolonged corrosion protection,particularly against galvanic corrosion in dissimilar joints.The findings suggest that these synthesized nanocontainers hold promise for various industrial applications,particularly in the context of friction stir welded(FSW)Ti-Mg dissimilar joints,providing valuable insights for the development of advanced materials designed to mitigate corrosion.

A comprehensive review of radiation effects on solder alloys and solder joints

In the realm of military and defence applications, exposure to radiation significantly challenges the performance and reliability of solder alloys and joints in electronic systems. This comprehensive review examines radiation-induced effects on solder alloys and solder joints in terms of microstructure and mechanical properties. In this paper, we evaluate the existing literature, including experimental studies and fundamental theory, to provide a comprehensive overview of the behavior of solder materials under radiation. A review of the literature highlights key mechanisms that contribute to radiation-induced changes in the microstructure, such as the formation of intermetallic compounds, grain growth,micro-voids and micro-cracks. Radiation is explored as a factor influencing solder alloy hardness,strength, fatigue and ductility. Moreover, the review addresses the challenges and limitations inherent in studying the effects of radiation on solder materials and offers recommendations for future research. It is crucial to understand radiation-induced effects on solder performance to design robust and radiationresistant electronic systems. A review of radiation effects on solder materials and their applications in electronics serves as a valuable resource for researchers, engineers, and practitioners in that field.

Microstructure,Corrosion and Mechanical Properties of Medium-Thick 6061-T6 Alloy/T2 Pure Cu Dissimilar Joints Produced by Double Side Friction Stir Z Shape Lap-Butt Welding

A novel double side friction stir Z shape lap-butt welding(DS-FSZW)process was proposed to achieve excellent mechanical properties of Al/Cu medium-thick dissimilar joints.The influence of welding parameters on weld microstructure and properties of DS-FSZW joint were systematically investigated.It indicated that defect-free medium-thick Al/Cu DS-FSZW joint could be achieved under an optimal welding parameter.DS-FSZW joint was prone to form void defects in the bottom of the second-pass weld.The recrystallization mechanisms at the top and middle of the weld nugget zone(WNZ)were continuous dynamic recrystallization(CDRX)and geometric dynamic recrystallization(GDRX).While the major recrystallization mechanism at the bottom of the WNZ was GDRX.DS-FSZW joint of the optimal welding condition with 850 r/min-400 mm/min was produced with a continuous thin and crack-free IMCs layer at the Al/Cu interface,and the maximum tensile strength of this joint is 160.57 MPa,which is equivalent to 65.54%of pure Cu base material.Moreover,the corrosion resistance of Al/Cu DS-FSZW joints also achieved its maximum value at the optimal welding parameter of 850 r/min-400 mm/min.It demonstrates that the DS-FSZW process can simultaneously produce medium-thick Al/Cu joints with excellent mechanical performance and corrosion resistance.

A statistical damage-based constitutive model for shearing of rock joints in brittle drop mode

Some rock joints exhibit significant brittleness,characterized by a sharp decrease in shear stress upon reaching the peak strength.However,existing models often fail to accurately represent this behavior and are encumbered by numerous parameters lacking clear mechanical significance.This study presents a new statistical damage constitutive model rooted in both damage mechanics and statistics,containing only three model parameters.The proposed model encompasses all stages of joint shearing,including the compaction stage,linear stage,plastic yielding stage,drop stage,strain softening stage,and residual strength stage.To derive the analytical expression of the constitutive model,three boundary conditions are introduced.Experimental data from both natural and artificial rock joints is utilized to validate the model,resulting in average absolute relative errors ranging from 3%to 8%.Moreover,a comparative analysis with established models illustrates that the proposed model captures stress drop and post-peak strain softening more effectively,with model parameters possessing clearer mechanical interpretations.Furthermore,parameter analysis is conducted to investigate the impacts of model parameters on the curves and unveil the relationship between these parameters and the mechanical properties of rock joints.Importantly,the proposed model is straightforward in form,and all model parameters can be obtained from direct shear tests,thus facilitating the utilization in numerical simulations.

Numerical simulation of formation mechanism of unloading joints in granitic pluton

The Beishan pluton in Gansu of China was selected as the simulated model.The simulation results indicate that the formation of unloading joints in granite is mainly influenced by the unloading rate of confin-ing pressure.Among the rates tested,the slowest unloading rate 0.025 MPa/s is found to be most conducive to the development of unloading joints.Therefore,a slower unloading rate is favourable for the occurrence of unloading joints.A series of simulations with varying initial depths of uplift ranging from 900 m to 200 m were conducted.The results confirm that when the specimen rises to a depth of 550-500 m,the unloading joints begin to form.The uplift from a depth of 700-500 m,with variations in both vertical and lateral un-loading rates,was simulated.The generation of unloading joints exhibits a negative correlation with vertical unloading and no correlation with lateral unloading,indicating that the unloading joints are mainly controlled by the unloading of vertical pressure.Throughout the simulation process,the vertical joints exhibit irregular and unrealistic regularity,suggesting a more complex formation mechanism than that of the unloading joints.

Superconducting joints using reacted multifilament MgB_(2)wires:A technology toward cryogen-free MRI magnets

The development of superconducting joining technology for reacted magnesium diboride(MgB_(2))conductors remains a critical challenge for the advancement of cryogen-free MgB_(2)-based magnets for magnetic resonance imaging(MRI).Herein,the fabrication of superconducting joints using reacted carbon-doped multifilament MgB_(2)wires for MRI magnets is reported.To achieve successful superconducting joints,the powder-in-mold method was employed,which involved tuning the filament protection mechanism,the powder compaction pressure,and the heat treatment condition.The fabricated joints demonstrated clear superconducting-to-normal transitions in self-field,with effective magnetic field screening up to 0.5 T at 20 K.To evaluate the interface between one of the MgB_(2)filaments and the MgB_(2)bulk within the joint,serial sectioning was conducted for the first time in this type of superconducting joint.The serial sectioning revealed space formation at the interface,potentially caused by the volume shrinkage associated with the MgB_(2)formation or the combined effect of the volume shrinkage and the different thermal expansion coefficients of the MgB_(2)bulk,the filament,the mold,and the sealing material.These findings are expected to be pivotal in developing MgB_(2)superconducting joining technology for MRI magnet applications through interface engineering.

Effect Mechanisms of Hygrothermal Environments on Failure of Single-Lap and Double-Lap CFRP-Aluminum Bolted Joints

The high demands for load-carrying capability and structural efficiency of composite-metal bolted joints trigger in-depth investigations on failure mechanisms of the joints in hygrothermal environments.However,few studies have been presented to exhaustively reveal hygrothermal effects on the failure of CFRP-metal bolted joints,which differ from CFRP-CFRP or metal-metal bolted joints because of the remarkably different material properties of CFRPs and metals.In this paper,hygrothermal effects on tensile failures of single-lap and double-lap CFRP-aluminum bolted joints were experimentally and numerically investigated.A novel numerical model,in which a hygrothermal-included progressive damage model of composites was established and elastic-plastic models of metals were built,was proposed to predict the failures of the CFRP-metal bolted joints in hygrothermal environments and validated by corresponding experiments.Different failure mechanisms of single-lap and double-lap CFRP-aluminum bolted joints,under 23°C/Dry and 70°C/Wet conditions,were revealed,respectively.It follows that both the collapse failures of the single-lap and double-lap bolted joints were dominated by the bearing failure of the CFRP hole laminate in the two conditions,indicating that the hygrothermal environment did not change the macro failure modes of the joints.However,the hygrothermal environment considerably shortened the damage propagation processes and reduced the strength of the joints.Besides,the hygrothermal environment weakened the load-transfer capability of the single-lap joint more severely than the double-lap joint because it aggravated the secondary bending effects of the single-lap joint obviously.

Damage Failure Analysis of Z-Pins Reinforced Composite Adhesively Bonded Single-Lap Joint

In order to study themechanical properties of Z-pins reinforced laminated composite single-lap adhesively bonded joint under un-directional static tensile load,damage failure analysis of the joint was carried out bymeans of test and numerical simulation.The failure mode and mechanism of the joint were analyzed by tensile failure experiments.According to the experimental results,the joint exhibits mixed failure,and the ultimate failure is Z-pins pulling out of the adherend.In order to study the failure mechanism of the joint,the finite element method is used to predict the failure strength.The numerical results are in good agreement with the experimental results,and the error is 6.0%,which proves the validity of the numerical model.Through progressive damage failure analysis,it is found that matrix tensile failure of laminate at the edge of Z-pins occurs first,then adhesive layer failure-proceeds at the edge of Z-pins,and finally matrix-fiber shear failure of the laminate takes place.With the increase of load,the matrix-fiber shear failure expands gradually in the X direction,and at the same time,the matrix tensile failure at the hole edge gradually extends in different directions,which is consistent with the experimental results.

Comparison of FSW and TIG welded joints in Al-Mg-Mn-Sc-Zr alloy plates

In order to study the welding process,microstructure and properties of Al-Mg-Mn-Sc-Zr alloy,comparative methods of friction stir welding（FSW） and tungsten inert gas（TIG） were applied to the two conditions of this alloy,namely hot rolled plate and cold rolled-annealed plate.The relationships between microstructures and properties of the welded joints were investigated by means of optical microscopy and transmission electron microscopy.Compared with the base metal,the strength of FSW and TIG welded joints decreased,and the FSW welding coefficients were higher than the TIG welding coefficients.The loss of substructure strengthening and a very little loss of precipitation strengthening of Al3（Sc,Zr） cause the decreased strength of FSW welded joint.But for the TIG welded joint,the disappearance of both the strain hardening and most precipitation strengthening effect of Al3（Sc,Zr） particles contributed to its softening.At the same time,the grains in weld nugget zone of FSW welded joints were finer than those in the molten zone of TIG welded joints.

Microstructure and mechanical properties of dissimilar pure copper/1350 aluminum alloy butt joints by friction stir welding

The dissimilar friction stir welding of pure copper/1350 aluminum alloy sheet with a thickness of 3 mm was investigated. Most of the rotating pin was inserted into the aluminum alloy side through a pin-off technique, and sound welds were obtained at a rotation speed of 1000 r/min and a welding speed of 80 mm/min. Complicated microstructure was formed in the nugget, in which vortex-like pattern and lamella structure could be found. No intermetallic compounds were found in the nugget. The hardness distribution indicates that the hardness at the copper side of the nugget is higher than that at the aluminum alloy side, and the hardness at the bottom of the nugget is generally higher than that in other regions. The ultimate tensile strength and elongation of the dissimilar welds are 152 MPa and 6.3%, respectively. The fracture surface observation shows that the dissimilar joints fail with a ductile-brittle mixed fracture mode durin~ tensile test.

Determination of local constitutive behavior and simulation on tensile test of 2219-T87 aluminum alloy GTAW joints

The local and global mechanical responses of gas tungsten arc welds（GTAW） of a 2219-T87 aluminum alloy were investigated with experiment and numerical simulation.Digital image correlation（DIC） was used to access the local strain fields in transversely loaded welds and to determine the local stress-strain curves of various regions in the joint.The results show that the DIC method is efficient to acquire the local stress-strain curves but the curves of harder regions are incomplete because the stress and strain ranges are limited by the weakest region.With appropriate extrapolation,the complete local stress-strain curves were acquired and proved to be effective to predict the tensile behavior of the welded joint.During the tensile process,the fracture initiates from the weld toes owing to their plastic strain concentrations and then propagates along the fusion line,finally propagates into the partially melted zone（PMZ）.