Optimization Of Alumina Particle Reinforced Bonding Process And Fracture Failure Research

Alumina particles were introduced into the adhesive layer of the 1.5mm thick5182 aluminum alloy sheet bonding joint.Process test research and parameter optimization were conducted on the adhesive layer alumina particle reinforced bonding based on the response surface method.A mechanical finite element model of the adhesive layer alumina particle reinforced bonding structure was established to probe into its fracture failure mechanism.The main contents and conclusions of this topic research mainly include:An experimental research on the adhesive layer alumina particle reinforced bonding process was carried out based on the BBD response surface method and with the particle size,particle mass fraction and adhesive layer thickness as process influencing factors.The response surface models of joint failure load and energy absorption value were established respectively.The results indicate that the factor producing the largest impact on joint failure load is the particle size;and the particle mass fraction affects the energy absorption value of the joint most.With the aid of the response surface models,the process parameter optimization analysis and experimental verification were carried out.The optimal process parameters for obtaining adhesive layer alumina particle reinforced bonding are as follows: particle size,0.047mm;adhesive layer thickness,0.594mm;particle volume fraction,1.5%.The test failure load and energy absorption value obtained according to the optimal bonding process parameters are 8,797.48 N and 93.073 J.The error of both theoretical calculations and test results fall within 5%,demonstrating the reliability of the regression model.A simulation study of the failure of the adhesive layer alumina particle reinforced bonded joint was conducted.The Python scripting language was adopted to establish a RVE random distribution geometric model for particles based on the Monte Carlo algorithm.And the ABAQUS software platform was used to introduce the cohesive force units between particles and matrixes and between matrixes in the adhesive layer.And a structural mechanics finite element analysis model of the adhesive layer was built to explore the fracture failure mechanism of the adhesive layer.The simulation analysis shows that the existence of particles in the adhesive layer has changed the crack propagation path,resulting in an increase in the length of the crack.This has thus increased the failure fracture energy,ultimately enhancing the mechanical properties of the bonded joint.The peak load and tensile modulus of the bonding layer will decrease with the increase in particle size and particle volume fraction.In the reinforcing system composed of the alumina particles and adhesive layer matrixes with smaller particle sizes,a later crack mean slower crack propagation path,contributing to the final larger crack growth size.When the particle volume fraction is reduced to 1.5%,the crack propagation rate of the crack in the matrix will be minimized and the crack propagation path size will be maximized.At this time,the bonding layer will have the highest strength.The simulation results are consistent with the test results.