Fracture toughness of structural adhesives for the automotive industry

Adhesive bonding is currently employed by automotive manufacturers to complement (or replace) welding in joining dissimilar materials. In order to reduce the impact on the existing manufacturing infrastructures, structural adhesives are deployed in the body shop but hardening is accomplished in the paint cure oven. Various adhesive formulations have been specifically developed for the implementation in the automotive manufacturing chain. However, it is very important to assess the mechanical behaviour of the joints which results from the peculiar curing strategy. In the present work, automotive grade single component epoxy and two component epoxy modified acrylic adhesives were evaluated. T-joints were fabricated using a cold rolled galvanized steel (FeP04) employed in the production of car body parts. The fracture toughness of the joints was determined using the test protocol proposed by the European Structural Integrity Society (ESIS). Optical microscopy was employed to ascertain the mechanisms of failure. The results indicated that both adhesives were able to provide a fairly good mechanical response with minimum preparation of the mating substrates. Moreover, the obtained values of fracture toughness were shown to be essentially independent of the adhesive layer thickness.