Comparison of the strength and energy absorption of adhesive-bonded with resistance spot-welded single-lap joints

mousavi, seyyed mohsen; mamduhi, seyyedeh maryam; marzbanrad, javad

doi:10.22068/ase.2025.731

Volume 15, Issue 4 (12-2025) ASE 2025, 15(4): 4900-4905 | Back to browse issues page

‎ 10.22068/ase.2025.731

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mousavi S M, mamduhi S M, marzbanrad J. Comparison of the strength and energy absorption of adhesive-bonded with resistance spot-welded single-lap joints. ASE 2025; 15 (4) :4900-4905
URL: http://ase.iust.ac.ir/article-1-731-en.html

Comparison of the strength and energy absorption of adhesive-bonded with resistance spot-welded single-lap joints

Seyyed mohsen Mousavi

, Seyyedeh maryam Mamduhi

, Javad Marzbanrad

Iran University of Science and Technology

Abstract: (737 Views)

In lightweight body-in-white design, joints must not only provide strength but also allow for ductility and sufficient energy absorption. In this study, Single Lap Joints (SLJs) made with adhesive bonding are compared experimentally with those joined by Resistance Spot Welding (RSW) in low-carbon steel sheets. The influence of overlap length (15 and 25 mm) and weld number (one or two spots) is examined. Tensile force–displacement tests, conducted at room temperature with a crosshead speed of 1 mm/min, revealed that extending the overlap from 15 to 25 mm improved the peak load, final displacement, and fracture energy of the adhesive joints. Among the tested configurations, double spot welds (2RSW) provided the greatest capacity and toughness. However, adhesive joints with a 25 mm overlap (AB25) exhibited higher strength than single spot welds (1RSW), while their ductility was comparable. The observed failure modes varied across the joint types. In resistance spot welds, failure occurred mainly through button pull-out, whereas adhesive joints exhibited a mixed adhesive–cohesive failure mode. In contrast, the 2RSW specimens displayed pull-out and necking sequences, reflecting load sharing between the weld nuggets. Overall, the findings suggest straightforward design guidelines. When maximum strength and energy absorption are required, two Spot Welds (2RSW) are the best choice. On the other hand, AB25 joints, with a 25 mm overlap, provide higher strength than single Spot Welds (1RSW).

Keywords: Adhesive bonding, Resistance spot welding, Single-lap joints, Energy absorption, Failure modes, Automotive steels

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Type of Study: Research | Subject: Body structure