When it comes to lightweight design of automotive wheels, hybrid designs consisting of a carbon composite wheel rim and a metallic, e.g., aluminum alloy, wheel disc offer significant potential. However, the conventionally used bolted joint between the two parts is complex and requires compromises in lightweight design due to the additional mechanical elements. Within this research, an adhesive joint for a hybrid wheel is developed in order to demonstrate its performance and lightweight potential. The main challenges are the reliable resistance against high structural loads during different load cases, as well as the residual stresses in the joint due to different thermal expansion rates of the composite and aluminum material. The developed joint combines an adhesive bond with a form-fitted geometry while still enabling an assembling process of the wheel disc in rotational direction. In addition, adaptations of the fiber layup in the rim area significantly reduce the thermal residual stresses in the joint by 47%. Subcomponent specimens, which represent the joint of an aluminum spoke with the composite rim, are manufactured and tested at different temperatures and load cases. The test results show sufficient strength of the adhesive joint as well as an improvement of the developed form-fitted joint compared to a basic adhesive bond. The adhesively joined wheel offers a lightweight potential of 6% compared to the bolted wheel.

/pdf/design-and-experimental-analysis-of-an-adhesive-joint-for-a-3dc6umlt.pdf

Design and Experimental Analysis of an Adhesive Joint for a Hybrid Automotive Wheel

FRP tendons and cables are increasingly being used in civil engineering structures due to their high strength-to-weight ratio and corrosion resistance. The bond anchorage factors, which characterize the bond strength between the FRP tendon/cable and the surrounding materials, play a critical role in determining the overall performance of the system. In this study, a series of tensile tests were conducted on FRP tendons/cables with different bond anchorage factors to evaluate their load-carrying capacity, load–displacement curve, and strain distribution. The study considered different types and surface shapes of FRP tendons/cables, and determined the influence of anchoring length, bonding medium type, and bonding medium thickness on the performance. The strain distribution of FRP tendons/cables at the anchorage end gradually increased along the loading section to the free end. A stress analysis model of the anchoring section was proposed and found to be consistent with the test results.

Experimental Study on Tensile Performance of FRP Tendons/Cables with Varied Bond Anchorage Factors

Since their introduction in the 1950s, composite materials have been extensively studied for their fatigue performance across various engineering fields. Numerous publications have documented experimental investigations into how these materials perform under different loading and environmental conditions. Fiber-reinforced polymer (FRP) composites are increasingly replacing metals due to their high strength and stiffness. These composites face various static and fatigue loads in service, necessitating fatigue tests to assess cyclic behavior. Unlike metals, where a single crack propagates to failure, composites exhibit complex fatigue damage with multiple micro-cracks forming early in the process. FRP composites serve as pivotal structural materials across diverse industries. Yet, before their incorporation into structures, meticulous testing of both test coupons and structurally representative samples is essential to evaluate their physical attributes, particularly their fatigue properties. Regrettably, the considerable expense entailed in fabricating coupons for these evaluations poses a notable hindrance to the extensive integration of fibre-reinforced polymer(FRP) into end products. The objective of this study is to forecast and simulate the fatigue lifespan of FRP composites. Extensive research in this domain will be outlined within this paper, encompassing diverse prediction methodologies employed to ascertain the fatigue endurance of these materials. 

Examining fatigue of fiber reinforced polymer: A comprehensive review

Fatigue life analysis of carbon fiber reinforced polymer (CFRP) components in hybrid adhesive joints

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Fatigue life analysis of carbon fiber reinforced polymer (CFRP) components in hybrid adhesive joints