Micro-structural features and material properties impact on adhesive metal joints via computational modeling and machine learning

Qiao, Yao; Taufique, M.F.N.; Simmons, Kevin L.

doi:10.1016/j.rsurfi.2025.100591

Title: Micro-structural features and material properties impact on adhesive metal joints via computational modeling and machine learning

Journal Article · Sun Jul 13 00:00:00 UTC 2025 · Results in surfaces and interfaces (Online)

DOI: https://doi.org/10.1016/j.rsurfi.2025.100591 · OSTI ID:2573956

^[1];

^[1]; Simmons, Kevin L. ^[1]

Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

The quality of structural bonding in practical applications depends on various factors arising from materials, pre-processing conditions, and manufacturing. Understanding how these factors influence bonding performance and determining their relative importance are of significant interest. Thus, this study evaluates the effects of microstructural features and material properties on the structural strength of adhesively-bonded metal joints at the submillimeter scale, utilizing a combination of Finite Element Modeling (FEM) and Machine Learning (ML) with Gradient Boosting Regression (GBR). The microstructural features include adhesive thickness, internal voids within the adhesive, adherend-adhesive interfacial voids, void size and volume fraction, and surface roughness. The material properties include the constitutive behavior of the adhesive, as well as the adherend-adhesive interfacial strength and fracture energy. The changes in structural strength and morphologies of the bonded metal structures with respect to different microstructural features and material properties were clarified by FEM. By further leveraging ML-GBR, the sequence of importance of these factors affecting bonding performance across various scenarios was summarized. This work provides valuable insights into the development of improved structural bonding for adhesive joints in industries such as automotive , aerospace, and beyond.

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Research Organization:: Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Vehicle Technologies Office (VTO)

Grant/Contract Number:: AC05-76RL01830

OSTI ID:: 2573956

Report Number(s):: PNNL-SA--206683

Journal Information:: Results in surfaces and interfaces (Online), Journal Name: Results in surfaces and interfaces (Online) Vol. 20; ISSN 2666-8459

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Title: Micro-structural features and material properties impact on adhesive metal joints via computational modeling and machine learning

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