Analyzing effects of surface roughness, voids, and particle–matrix interfacial bonding on the failure response of a heterogeneous adhesive

• Published in: Computer methods in applied mechanics and engineering Vol. 346; pp. 410 - 439
• Main Authors: Liang, Bowen, Nagarajan, Anand, Ahmadian, Hossein, Soghrati, Soheil
• Format: Journal Article
• Language: English
• Published: Amsterdam Elsevier B.V 01.04.2019; Elsevier BV
• Subjects: Adhesives; Algorithms; Bonding strength; Cohesive damage; Computed tomography; Computer simulation; Damage assessment; Failure; Finite element; Finite element method; Heterogeneous adhesive; Image reconstruction; Interfacial bonding; Iterative methods; Mathematical analysis; Mesh generation; Microstructure; Microstructure reconstruction; Silicon dioxide; Surface roughness; Surface roughness effects; Three dimensional models; Cohesive damage; Surface roughness; Heterogeneous adhesive; Finite element; Microstructure reconstruction
• ISSN: 0045-7825; 1879-2138
• DOI: 10.1016/j.cma.2018.12.010

An automated computational framework is introduced to link the microstructure to the micromechanical behavior of a heterogeneous adhesive composed of an epoxy matrix and embedded silica particles. A new reconstruction algorithm is employed to synthesize 3D periodic microstructural models of this materials system based on morphological and statistical data extracted from micro-computed tomography images. A non-iterative mesh generation algorithm is implemented in parallel to transform resulting virtual microstructures into finite element (FE) models. The continuum ductile and cohesive damage models used for simulating the adhesive’s failure response are calibrated with experimental data and the statistical representative volume element (SRVE) is identified. We have then carried out several high-fidelity FE simulations to investigate the effects of pre-existing voids in the adhesive layer, surface roughness of adherends, and the bonding strength along particles–matrix interfaces on the failure response of the adhesive subject to tensile, compressive, and shear loads. •Integrated computational framework to create realistic FE models of adhesive microstructure.•Employed ductile damage and cohesive–contact models to simulate mechanical behavior.•Performed a comprehensive study to determine appropriate size of statistical RVE.•Analyzed effects of various microstructural features on failure response.•Outcome: adherend surface roughness and voids have negligible impact on strength and toughness.