Metal/polymer adhesive joints, valued for their high strength and lightweight properties in automotive components, are susceptible to debonding under dynamic loading, potentially compromising vehicle safety and reliability. The unclear evolution of bond strength with adhesive layer thickness (ALT) under dynamic loading necessitates further investigation to enhance bond strength. We systematically investigate the effects of the ALT and strain rate on the bond strength and reliability of aluminum (Al)/polymethyl methacrylate (PMMA) joints under dynamic loading. Using split Hopkinson pressure bar (SHPB) experiments and high-speed camera imaging, we observe that, contrary to the trend under quasi-static loading, the joints achieve maximum bond strength at a strain rate of ∼650 s−1 and the corresponding ALT of approximately 1.00 mm, which is 331.5% higher than that of the joints within a thinner ALT. The failure mechanisms of joints with different ALTs are revealed through a combination of experiment and simulation. Under the optimal ALT, the failure mechanism changes from interfacial failure to mixed failure due to the change of stress distribution. This study can provide valuable insights and theoretical foundations for the structural design and operational reliability of high-strength adhesive joints under dynamic loading.
VasconcelosRLOliveiraGHMAmancio-FilhoST, et al.Injection overmolding of polymer-metal hybrid structures: a review. Polym Eng Sci2023; 63(3): 691–722.
2.
TangYRenYZhaoW, et al.Mechanical properties of all-C/C composite hybrid bonded/bolted joints. J Reinforc Plast Compos2023; 42(7-8): 377–390.
3.
BarakatAADarrasBMNazzalMA, et al.A comprehensive technical review of the friction stir welding of metal-to-polymer hybrid structures. Polym2023; 15(1): 220.
4.
JeongJSom KangDIl JungY, et al.Effect of laser surface texturing pattern on mechanical properties in metal-polymer direct joining. Opt Laser Technol2025; 181: 112049.
5.
ZhangRLiJDingJ, et al.Simulative and experimental study of metal/polymer interfacial dynamic shear response. J Mater Sci2023; 58(32): 13080–13099.
6.
DerazkolaHAKhodabakhshiFSimchiA. Friction-stir lap-joining of aluminium-magnesium/poly-methyl-methacrylate hybrid structures: thermo-mechanical modelling and experimental feasibility study. Sci Technol Weld Join2018; 23(1): 35–49.
7.
GenedyMChennareddyRSolimanEM, et al.Improving shear strength of bolted joints in pultruded glass fiber reinforced polymer composites using carbon nanotubes. J Reinforc Plast Compos2017; 36(13): 958–971.
8.
ShinYQiaoYNiY, et al.Interfacial bond characterization of epoxy adhesives to aluminum alloy and carbon fiber-reinforced polyamide by vibrational spectroscopy. Surf Interfaces2023; 42: 103346.
9.
CuiCLiuW. Recent advances in wet adhesives: adhesion mechanism, design principle and applications. Prog Polym Sci2021; 116: 101388.
10.
PanZFuQWangM, et al.Designing nanohesives for rapid, universal, and robust hydrogel adhesion. Nat Commun2023; 14(1): 5378.
11.
GrujicicMSellappanVKotrikaS, et al.Suitability analysis of a polymer-metal hybrid technology based on high-strength steels and direct polymer-to-metal adhesion for use in load-bearing automotive body-in-white applications. J Mater Process Technol2009; 209(4): 1877–1890.
12.
FeistauerEEdos SantosJFAmancio-FilhoST. A review on direct assembly of through-the-thickness reinforced metal-polymer composite hybrid structures. Polym Eng Sci2019; 59(4): 661–674.
13.
NaikRKPandaSKRacherlaV. A new method for joining metal and polymer sheets in sandwich panels for highly improved interface strength. Compos Struct2020; 251: 112661.
14.
BulaKSterzynskiTPiaseckaM, et al.Deformation mechanism in mechanically coupled polymer-metal hybrid joints. Materials2020; 13(11): 2512.
15.
Ochoa-PutmanCVaidyaUK. Mechanisms of interfacial adhesion in metal-polymer composites - effect of chemical treatment. Compos Part A-Appl S2011; 42(8): 906–915.
16.
Amancio-FilhoSTdos SantosJF. Joining of polymers and polymer-metal hybrid structures: recent developments and trends. Polym Eng Sci2009; 49(8): 1461–1476.
17.
YangKFengHLiP, et al.The effects of environments and adhesive layer thickness on the failure modes of composite material bonded joints. Sci Rep2024; 14(1): 22776.
18.
NaitoKOntaMKogoY. The effect of adhesive thickness on tensile and shear strength of polyimide adhesive. Int J Adhesion Adhes2012; 36: 77–85.
19.
SekiguchiYSatoC. Experimental investigation of the effects of adhesive thickness on the fracture behavior of structural acrylic adhesive joints under various loading rates. Int J Adhesion Adhes2021; 105: 102782.
20.
TerasakiNFujioYShimamotoK, et al.Mechanoluminescent visualization for considering effect of bondline thickness and overlap length on single lap joint. Int J Adhesion Adhes2024; 134: 103786.
21.
BaneaMDDa SilvaLFMCampilhoRDSG. The effect of adhesive thickness on the mechanical behavior of a structural polyurethane adhesive. J Adhes2015; 91(5): 331–346.
22.
da SilvaLFMRodriguesTNSSFigueiredoMAV, et al.Effect of adhesive type and thickness on the lap shear strength. J Adhes2006; 82(11): 1091–1115.
23.
GleichDMVan ToorenMJLBeukersA. Analysis and evaluation of bondline thickness effects on failure load in adhesively bonded structures. J Adhes Sci Technol2001; 15(9): 1091–1101.
24.
YousefsaniSATahaniM. Analytical solutions for adhesively bonded composite single-lap joints under mechanical loadings using full layerwise theory. Int J Adhesion Adhes2013; 43: 32–41.
25.
MachadoJJMMarquesEASda SilvaLFM. Adhesives and adhesive joints under impact loadings: an overview. J Adhes2018; 94(6): 421–452.
26.
FengPZhaoJDaiF, et al.Mechanical behaviors of conjugate-flawed rocks subjected to coupled static-dynamic compression. Acta Geotech2022; 17(5): 1765–1784.
27.
RaykhereSLKumarPSinghRK, et al.Dynamic shear strength of adhesive joints made of metallic and composite adherents. Mater Des2010; 31(4): 2102.
28.
GoglioLRossettoM. Impact rupture of structural adhesive joints under different stress combinations. Int J Impact Eng2008; 35(7): 635–643.
29.
PeirsJVerleysenPVan PaepegemW, et al.Determining the stress-strain behaviour at large strains from high strain rate tensile and shear experiments. Int J Impact Eng2011; 38(5): 406–415.
30.
AngelidiMVassilopoulosAPKellerT. Ductility, recovery and strain rate dependency of an acrylic structural adhesive. Constr Build Mater2017; 140: 184–193.
31.
LambiaseFGrossiVPaolettiA. High-speed joining of hybrid metal-polymer joints during the friction-assisted joining process. Compos Struct2022; 280: 114890.
32.
CarradoAFaerberJNiemeyerS, et al.Metal/polymer/metal hybrid systems: towards potential formability applications. Compos Struct2011; 93(2): 715–721.
33.
JiaZYuanGFengX, et al.Shear properties of polyurethane ductile adhesive at low temperatures under high strain rate conditions. Compos Part B-Eng2019; 156: 292–302.
34.
LiJDingJWeiJ, et al.Dynamic response of metal/polymer bilayer composite with optimized surface porosity by experiment and simulation. J Mater Res Technol2023; 24: 1626–1637.
35.
AliUKarimKBuangN. A review of the properties and applications of poly (methyl methacrylate) (PMMA). Polym Rev2015; 55(4): 678–705.
36.
AltunokFEDe PasqualeG. Numerical cohesive zone modeling (CZM) of self-anchoring AM metal-CFRP joints. Frat Integrita Strut2024; 18(68): 280–295.
37.
MengHLiQM. Correlation between the accuracy of a SHPB test and the stress uniformity based on numerical experiments. Int J Impact Eng2003; 28(5): 537–555.
38.
LiXZouYZhouZ. Numerical simulation of the rock SHPB test with a special shape striker based on the discrete element method. Rock Mech Rock Eng2014; 47(5): 1693–1709.
ChengJSunYYuY, et al.Effect of interference magnitude on ultimate strength and failure analysis of aluminium-drill-pipe-body-tool-joint-assemblies with Johnson-Cook model. Eng Fail Anal2022; 137: 106281.
41.
DuQLiuFLeiQ. Numerical simulation of PMMA impact based on the J-C constitutive and damage models under hydrostatic pressure loading. Appl Sci-Basel2023; 13(15): 8640.
42.
LiSSuQWangX, et al.Modification of the Johnson-Cook model for metal at a wide range of strain rates and application in the dynamic response of honeycomb panels. Model Simul Mater Sc2022; 30(8): 085012.
43.
AkramSJafferySKhanM, et al.Numerical and experimental investigation of Johnson-Cook material models for aluminum (Al 6061-T6) alloy using orthogonal machining approach. Adv Mech2018; 10(9): 168781401879779.
44.
ZhangHShuklaMRajendranA, et al.Simulations of single and double shock experiments using generalized interpolation material point method with a noise control strategy. Comput Times Part Mech2023; 10(6): 1795–1809.
45.
RochaAAkhavan-SafarACarbasR, et al.Numerical analysis of mixed-mode fatigue crack growth of adhesive joints using CZM. Theor Appl Fract Mech2020; 106: 102493.
46.
ZaeriAGoogarchinH. Analysis of automotive mixed-adhesive joints weakened by moist conditions: experimental characterization and numerical simulation using cohesive zone model. Fatigue Fract Eng M2019; 42(4): 929–942.
47.
CarvalhoUCampilhoR. Validation of pure tensile and shear cohesive laws obtained by the direct method with single-lap joints. Int J Adhesion Adhes2017; 77: 41–50.
48.
CampilhoRBaneaMPintoA, et al.Strength prediction of single- and double-lap joints by standard and extended finite element modelling. Int J Adhesion Adhes2011; 31(5): 363–372.
49.
CampilhoRBaneaMNetoJ, et al.Modelling adhesive joints with cohesive zone models: effect of the cohesive law shape of the adhesive layer. Int J Adhesion Adhes2013; 44: 48–56.
Supplementary Material
Please find the following supplemental material available below.
For Open Access articles published under a Creative Commons License, all supplemental material carries the same license as the article it is associated with.
For non-Open Access articles published, all supplemental material carries a non-exclusive license, and permission requests for re-use of supplemental material or any part of supplemental material shall be sent directly to the copyright owner as specified in the copyright notice associated with the article.
