Kent E. Nielsen

Significance of Peel Test Speed on Interface Strength in Cohesive Zone Modeling

The analysis of the experimental peel test data for obtaining the adhesion fracture energy of an adhesively laminated polymer to the sheet metal surface is considered. The experimental results of the 180° peel test on two types of polymer laminated sheet metal at three different peel speeds are analyzed by two methodological approaches in cohesive zone modeling. These approaches are linear-elastic stiffness approach and critical maximum stress approach. Comparing the results of these two approaches reveals the significance of the peel test speed on the interface strength determination for cohesive zone modeling. It is concluded that a “reference” peel speed may exist at which the interface strength is equal to the yield strength of the peel arm material. A constitutive equation has been proposed which relates the interface strength to the peel test velocity by using the reference peel speed and its corresponding peel arm yield strength.

Influence of metallic substrate surface engineering on peel resistance of adhesively bonded polymer film

The peel resistance of adhesively bonded polymer films to a stainless steel sheet substrate (SSSS) with different engineered surface characteristics was examined in two different loading directions and for two different peel speeds. The SSSS was laminated with two thin polymeric adherends using two different pressure-sensitive adhesives. The SSSS surface was altered by grinding and knurling techniques before lamination and the effects of surface alterations on peel resistance were compared with peel resistance of the adherend from as-received SSSS with a bright annealed surface condition. For ground surface, an increase in adherend peel resistance was observed and the increase was attributed to increase in contact area between the adhesive and SSSS surface. For knurled surfaces which involved deeper and less frequent grooves, however, a decrease in peel resistance was observed. This was attributed to a more complex stress state at the peel front in the SSSS groove region during peeling. An increase in peel speed enhanced the peel resistance from both ground and knurled surfaces.

Thermal wrinkling behavior of formable decorative film laminates

This paper focuses on wrinkle development in decorative film laminates during heating operations with the goal to understand their driving factors and develop strategies to overcome such defects. The study looked at temperature and heating rate effects on the wrinkling behavior of a commercial black-out film laminated onto a metal substrate. The 135℃ threshold temperature identified for our film under which no wrinkles formed, related to the stiffness of its different construction layers. Heating rate was also noted by this study to be an important parameter in wrinkling; values between 1℃ and 350℃/min were tested. It was possible to exceed the threshold temperature stated above without wrinkling when the heating rate was sufficiently low (closer to 1℃/min, though less than 50℃/min was often sufficient depending on the final temperature). The heating rate effect is believed to be related to the time-dependent viscoelastic response of the compliant layer in relation to building thermal stresses.

Effect of Deformation-induced Residual Stress on Peel Strength of Polymer Laminated Sheet Metal

The adhesion between adhesively bonded polymer film and a metallic sheet substrate in a polymer laminated sheet metal (PLSM) subjected to large deformation, such as in a forming process, is influenced by two deformation-induced factors. These are (i) evolution of surface roughness of metallic substrate with applied strain and (ii) development of residual stress in the polymer adherend (polymer film with a thin uniform adhesive layer on one side) arising from significant differences in the deformation behavior of metal and polymeric components. A new experimental methodology was devised in this study to decouple the effects of substrate surface roughness and residual stress on interfacial peel strength (IPS) of uniaxially deformed PLSMs. This methodology was based on 180° peel testing of PLSM specimens prepared under two different lamination conditions, one involving systematic pre-straining in uniaxial tension of the metallic substrate prior to laminations and the other involving post-lamination pre-straining of the PLSM. The role of pre-strain and peel test speed, for the above laminations conditions, were critically analyzed for their effect on IPS of two differently tailored PLSM systems. The IPS results were attributed to the effect of deformation-induced residual stress and metallic surface roughness. The analysis suggests that IPS is strongly dependent upon the residual stress induced by uniaxial deformation but only marginally on substrate surface roughness depending upon the constituents (film and adhesive) of the adherend. The magnitude of pre-strain was inversely and non-linearly related to IPS for both deformed PLSMs. Peel test speed, on the other hand, showed a more complex behavior in terms of IPS for the two PLSM systems.