A temperature- and conversion-dependent cohesive zone approach for the calculation of process-induced damage in adhesive bondlines of multi-material structures

Abstract

Adhesive bondlines in multi-material car bodies underlie various influences from the production process. Especially the mismatch of the coefficient of thermal expansion during the oven process of cathodic dip coating can cause damage and weaken the joint strength. Temperature-dependent mechanical properties and the increasing conversion that describes the degree of cure of the adhesive are important parameters affecting the adhesive bondlines during production. To take these effects into account in numerical simulations, a cohesive zone approach, which is commonly used to model adhesive bondlines in structural simulations, is adapted to a one-component, hot curing, structural epoxy adhesive for body-in-white manufacturing and is extended with a reaction kinetic model of the curing reaction, conversion-dependent material properties, and temperature dependency. The investigation of the material properties using a rheometer and differential scanning calorimetry experiments is described. Furthermore, the cohesive zone model is presented and an experimental validation of the model using customized tapered-double-cantilever-beam specimens to investigate the crack opening behavior of incompletely cured adhesives shows a good agreement with the numerical data.

Keywords

Epoxy cure reaction kinetic cohesive zone model cathodic dip coating process adhesive damage

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