Comparison of the strength of resistance spot-welded, bonded, and hybrid single lap joints: A numerical investigation
Robust and lightweight joining techniques are crucial for good performance and safety in advanced engineering applications, particularly in the automotive and aerospace sectors. While traditional methods such as bolting, riveting, and resistance spot welding have been central to structural assembly,...
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Elsevier
2025-03-01
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| Series: | Results in Engineering |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2590123024021145 |
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| author | Murat Demiral Ali Mamedov |
| author_facet | Murat Demiral Ali Mamedov |
| author_sort | Murat Demiral |
| collection | DOAJ |
| description | Robust and lightweight joining techniques are crucial for good performance and safety in advanced engineering applications, particularly in the automotive and aerospace sectors. While traditional methods such as bolting, riveting, and resistance spot welding have been central to structural assembly, they face limitations under modern engineering demands like higher strength, weight reduction, improved fatigue life and damage tolerance. This study investigates the mechanical performance of resistance spot-welded, adhesively bonded, and hybrid single lap joints, focusing on the effects of spot-weld diameter and the adhesive layer's ductile-brittle properties. The ABAQUS/Explicit finite element program was employed to model three-dimensional adhesively bonded, resistance spot welding, and hybrid (combination of the first two) joints made of advanced high-strength steel (AHSS) DP1000. Cohesive zone elements simulated adhesive damage initiation and propagation as well as the pull-out failure. The models were validated against experimental data from literature. The study examined three adhesives (SikaPower 423 L1, Araldite AV138, Araldite 2015), three spot-welding diameters, and three adherend thicknesses to provide detailed insights for optimizing joint designs, enhancing reliability and durability in complex engineering applications. The results indicate that the hybrid joint employing SikaPower 423 L1 adhesive achieved an energy absorption of 14.4 J, representing a 22 % improvement over the resistance spot-welded (RSW) joint. Notably, the hybrid joint with Araldite 2015 adhesive exhibited the highest energy absorption, reaching 23.1 J—an impressive 96 % increase compared to RSW. Following this, the hybrid joint using Araldite AV138 adhesive demonstrated an energy absorption of 18.1 J, marking a 53 % enhancement over RSW. |
| format | Article |
| id | doaj-art-f9840e25f20d48649dc3e7b8aff5c6c9 |
| institution | Kabale University |
| issn | 2590-1230 |
| language | English |
| publishDate | 2025-03-01 |
| publisher | Elsevier |
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| series | Results in Engineering |
| spelling | doaj-art-f9840e25f20d48649dc3e7b8aff5c6c92025-01-04T04:56:57ZengElsevierResults in Engineering2590-12302025-03-0125103871Comparison of the strength of resistance spot-welded, bonded, and hybrid single lap joints: A numerical investigationMurat Demiral0Ali Mamedov1Corresponding author.; College of Engineering and Technology, American University of the Middle East, Egaila 54200, KuwaitCollege of Engineering and Technology, American University of the Middle East, Egaila 54200, KuwaitRobust and lightweight joining techniques are crucial for good performance and safety in advanced engineering applications, particularly in the automotive and aerospace sectors. While traditional methods such as bolting, riveting, and resistance spot welding have been central to structural assembly, they face limitations under modern engineering demands like higher strength, weight reduction, improved fatigue life and damage tolerance. This study investigates the mechanical performance of resistance spot-welded, adhesively bonded, and hybrid single lap joints, focusing on the effects of spot-weld diameter and the adhesive layer's ductile-brittle properties. The ABAQUS/Explicit finite element program was employed to model three-dimensional adhesively bonded, resistance spot welding, and hybrid (combination of the first two) joints made of advanced high-strength steel (AHSS) DP1000. Cohesive zone elements simulated adhesive damage initiation and propagation as well as the pull-out failure. The models were validated against experimental data from literature. The study examined three adhesives (SikaPower 423 L1, Araldite AV138, Araldite 2015), three spot-welding diameters, and three adherend thicknesses to provide detailed insights for optimizing joint designs, enhancing reliability and durability in complex engineering applications. The results indicate that the hybrid joint employing SikaPower 423 L1 adhesive achieved an energy absorption of 14.4 J, representing a 22 % improvement over the resistance spot-welded (RSW) joint. Notably, the hybrid joint with Araldite 2015 adhesive exhibited the highest energy absorption, reaching 23.1 J—an impressive 96 % increase compared to RSW. Following this, the hybrid joint using Araldite AV138 adhesive demonstrated an energy absorption of 18.1 J, marking a 53 % enhancement over RSW.http://www.sciencedirect.com/science/article/pii/S2590123024021145Resistance spot welding (RSW)Adhesively bonded jointsHybrid jointsSingle lap joint strengthDuctile-brittle adhesive characteristics |
| spellingShingle | Murat Demiral Ali Mamedov Comparison of the strength of resistance spot-welded, bonded, and hybrid single lap joints: A numerical investigation Results in Engineering Resistance spot welding (RSW) Adhesively bonded joints Hybrid joints Single lap joint strength Ductile-brittle adhesive characteristics |
| title | Comparison of the strength of resistance spot-welded, bonded, and hybrid single lap joints: A numerical investigation |
| title_full | Comparison of the strength of resistance spot-welded, bonded, and hybrid single lap joints: A numerical investigation |
| title_fullStr | Comparison of the strength of resistance spot-welded, bonded, and hybrid single lap joints: A numerical investigation |
| title_full_unstemmed | Comparison of the strength of resistance spot-welded, bonded, and hybrid single lap joints: A numerical investigation |
| title_short | Comparison of the strength of resistance spot-welded, bonded, and hybrid single lap joints: A numerical investigation |
| title_sort | comparison of the strength of resistance spot welded bonded and hybrid single lap joints a numerical investigation |
| topic | Resistance spot welding (RSW) Adhesively bonded joints Hybrid joints Single lap joint strength Ductile-brittle adhesive characteristics |
| url | http://www.sciencedirect.com/science/article/pii/S2590123024021145 |
| work_keys_str_mv | AT muratdemiral comparisonofthestrengthofresistancespotweldedbondedandhybridsinglelapjointsanumericalinvestigation AT alimamedov comparisonofthestrengthofresistancespotweldedbondedandhybridsinglelapjointsanumericalinvestigation |