TRANSPORT TECHNICS. INVESTIGATION OF ELEMENTS. RELIABILITY
Evaluation of Adhesively Bonded Joints for Repair of Exterior Automotive Plastic Parts
- 1 Technical University of Košice, Faculty of Mechanical Engineering, Department of Automotive Production, Košice, Slovakia
- 2 Technical University of Košice, Faculty of Mechanical Engineering, Department of Technology, Materials and Computer Aided Manufacturing, Košice, Slovakia
Abstract
This paper deals with the possibility of renovating exterior plastic automotive components using adhesive bonding technology. The research focuses on the evaluation of the shear strength of adhesive joints formed using adhesive systems commonly applied in automotive repair practice. The experimental investigation was carried out using selected adhesives, and the shear strength of the bonded joints was evaluated. To simulate real operating conditions of vehicles, accelerated laboratory tests were performed in which the bonded joints were exposed to various degradation environments. Subsequently, changes in the shear strength of the adhesive joints were evaluated after their exposure to these conditions. The study also examined the influence of road de-icing agents commonly used in winter road maintenance on the quality and integrity of the adhesive joints. Based on the analysis of fracture surfaces, the failure mechanisms of the joints were identified and classified as adhesive or cohesive failure. The obtained results provide a basis for assessing the applicability of adhesive bonding technology for the renovation of exterior plastic automotive components and contribute to the optimization of repair procedures used in automotive maintenance practice.
References
- DACHEV, D., KAZILAS, M., ALFANO, G., OMAIREY, S. Towards Reliable Adhesive Bonding: A Comprehensive Review of Mechanisms, Defects, and Design Considerations. Materials. 2025, vol. 18, no. 12, art. 2724. ISSN 1996-1944. DOI: 10.3390/ma18122724.
- RODRIGUES, V. C. M. B., KASAEI, M. M., MARQUES, E. A. S., CARBAS, R. J. C., DA SILVA, L. F. M. Adhesive bonding in automotive battery pack manufacturing and dismantling: a review. Discover Mechanical Engineering. 2025, vol. 4, no. 1, art. 25. ISSN 2731-6564. DOI: 10.1007/s44245-025-00107-5.
- AKHAVAN-SAFAR, A., MARQUES, E. A. S., CARBAS, R. J. C., DA SILVA, L. F. M. Structural Adhesive Bonding for Automotive Applications. 1st ed. Amsterdam: Elsevier, 2025. 384 p. ISBN 978-0-443-23912-0.
- PARK, S. K., SHIN, J. H., CHO, H. J. Dissimilar material bonding technology for lightweight future mobility: A review. International Journal of Adhesion and Adhesives. 2024, vol. 128, art. 103616. ISSN 0143-7496. DOI: 10.1016/j.ijadhadh.2023.103616.
- ZHANG, Y. S., LI, G. Y., SENKARA, J. Current Research and Challenges in Innovative Technology of Joining Dissimilar Materials for Electric Vehicles. In: Advanced High Strength Steel and Press Hardening: Proceedings of the 4th International Conference (ICHSU2018). Singapore: World Scientific, 2019, pp. 363–380. ISBN 978-981-3277-97-7.
- INTROSPECTIVE MARKET RESEARCH. Automotive Adhesives Market: Global Industry Analysis and Forecast 2025–2035. Report, 2025. Available online: https://introspectivemarketresearch.com/reports/automotive-adhesives-market/.
- TÜREL, T., CRISTADORO, A. M., LINNENBRINK, M., TOMOVIĆ, Ž. Harnessing Imine Chemistry for the Debonding-on-Demand of Polyurethane Adhesives. ACS Applied Materials & Interfaces. 2025, vol. 17, no. 1, pp. 1234–1245. ISSN 1944-8244. DOI: 10.1021/acsami.4c19435.
- HYDER, M. J., GODLEMAN, J., CHIPPINDALE, A. M. et al. Thermally and Base-Triggered "Debond-on-Demand" Chain-Extended Polyurethane Adhesives. Macromolecules. 2025, vol. 58, no. 1, pp. 234–247. ISSN 0024-9297. DOI: 10.1021/acs.macromol.4c02775.
- DEMIRAL, M. Strength in Adhesion: A Multi-Mechanics Review Covering Tensile, Shear, Fracture, Fatigue, Creep, and Impact Behavior of Polymer Bonding in Composites. Polymers. 2025, vol. 17, no. 19, art. 2600. ISSN 2073-4360. DOI: 10.3390/polym17192600.
- ASSEMBLY MAGAZINE. Structural Adhesives for Automotive Assembly. August 2025. Available online: https://www.assemblymag.com/articles/99405-structural-adhesives-for-automotive-assembly.
- BAEK, D., SIM, K.-B., KIM, H.-J. Mechanical Characterization of Core-Shell Rubber/Epoxy Polymers for Automotive Structural Adhesives as a Function of Operating Temperature — Polymers, 2021, vol. 13, no. 5, art. 734. DOI: 10.3390/polym13050734.
- DUPONT. Driving the future of EV battery assembly with adhesives. White paper, January 2025. Available online: https://chargedevs.com/whitepapers/driving-the-future-of-ev-battery-assembly-with-adhesives/.
- DOMITNER, J., SILVAYEH, Z., SOMMITSCH, C., GUBELJAK, N. Load-Bearing Capacities and Fracture Modes of Self-Piercing-Riveted, Adhesive-Bonded and Riv-Bonded Aluminum Joints at Quasi-Static and Cyclic Loadings. Journal of Materials Engineering and Performance. 2023, vol. 32, no. 4, pp. 1789–1801. ISSN 1059-9495. DOI: 10.1007/s11665-022-07677-5.
- ADARSH, S. J., NATARAJAN, A. Review on the advancements and relevance of emerging joining techniques for aluminium to polymers/carbon fibre-reinforced polymer lightweight hybrid structures. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications. 2022, vol. 236, no. 7, pp. 1283–1310. ISSN 1464-4207. DOI: 10.1177/14644207221090331.
- SCHANZ, J. et al. Adhesively bonded CFRP/Al joints: Influence of the surface pretreatment on corrosion during salt spray test. Materials and Corrosion. 2022, vol. 73, no. 4, pp. 567–582. ISSN 0947-5117. DOI: 10.1002/maco.202112752.
- KARTHIKEYAN, N., NAVEEN, J. Progress in adhesive-bonded composite joints: A comprehensive review. Journal of Reinforced Plastics and Composites. 2025, vol. 44, no. 3-4, pp. 145–178. ISSN 0731-6844. DOI: 10.1177/07316844241248236.
- HAN, L., CHRYSANTHOU, A., O'SULLIVAN, J. M. Self-piercing riveting—a review. International Journal of Advanced Manufacturing Technology. 2017, vol. 92, no. 5–8, pp. 1777–1824. ISSN 0268-3768. DOI: 10.1007/s00170-017-0156-x.
- ANG, H. Q. An Overview of Self-piercing Riveting Process with Focus on Joint Failures, Corrosion Issues and Optimisation Techniques. Chinese Journal of Mechanical Engineering. 2021, vol. 34, art. 2. ISSN 1000-9345. DOI: 10.1186/s10033-020-00526-3.
- DOMITNER, J., SILVAYEH, Z., PREDAN, J. et al. Riv-Bonding of Aluminum Alloys with High-Strength Steels against the Favorable Joining Direction. Journal of Materials Engineering and Performance. 2022, vol. 31, no. 6, pp. 4567–4581. ISSN 1059-9495. DOI: 10.1007/s11665-022-06647-1.
- STAMP, C.-H., STUMPP, J., CALVINO, C. Adhesives with Debonding-On-Demand Capability: Leveraging Responsive Microcapsules for Mechanically-Induced Debonding. Advanced Materials. 2025, vol. 37, no. 12, art. 2414308. ISSN 0935-9648. DOI: 10.1002/adma.202414308.
- EVONIK INDUSTRIES. Evonik unveils innovative "Debonding on Demand" concept for more sustainable adhesives. Press release, April 2025. Available online: https://www.evonik.com/en/news/press-releases/2025/04/evonik-unveils-innovative--debonding-on-demand--concept-for-more.html.