Instituto de Ciência e Inovação em Engenharia Mecânica e Engenharia Industrial

Despite offering very attractive advantages over traditional joining methods, one of the setbacks of adhesive bonding is its long-term strength in aggressive environments, such as environments with high moisture and extreme temperatures. With the rise of new lightweight materials and their recent use in everyday vehicles, transportation industries have been very interested in determining the long-term behavior of adhesive joints. The aim is to build durable, lighter vehicles, which consume less energy and emit less pollution. The two main factors that affect the strength of vehicle adhesive joints are exposure to moist environments and high and low temperatures. There are some works concerning the effect of these two factors separately and some predictive models have been developed, which help the engineer to design reliable, safe, and efficient adhesive joints. However, the combined effect of temperature and moisture is not yet totally understood. This paper presents a review on the temperature and moisture degradation of adhesive joints.

The machining process is still a very relevant process in today’s industry, being used to produce high quality parts for multiple industry sectors. The machining processes are heavily researched, with the focus on the improvement of these processes. One of these process improvements was the creation and implementation of tool coatings in various machining operations. These coatings improved overall process productivity and tool-life, with new coatings being developed for various machining applications. TiAlN coatings are still very present in today’s industry, being used due to its incredible wear behavior at high machining speeds, high mechanical properties, having a high-thermal stability and high corrosion resistance even at high machining temperatures. Novel TiAlN-based coatings doped with Ru, Mo and Ta are currently under investigation, as they show tremendous potential in terms of mechanical properties and wear behavior improvement. With the improvement of deposition technology, recent research seems to focus primarily on the study of nanolayered and nanocomposite TiAlN-based coatings, as the thinner layers improve drastically these coating’s beneficial properties for machining applications. In this review, the recent developments of TiAlN-based coatings are going to be presented, analyzed and their mechanical properties and cutting behavior for the turning and milling processes are compared.

Thermoset fiber reinforced composites, widely used in current structural applications, have complex repair procedures and generates significant amounts of scrap due to its recycling difficulties, which does not comply with the most recent environmental restrictions. These disadvantages may be overcome by using a thermoplastic matrix phase, which is very suitable to be joined and repaired by local melting, making the composite material fully recyclable. This work presents a literature review on the joining methods applicable to thermoplastic based composites and their potential applications to be used as repair procedures in structural elements. The effectiveness of selected adhesive and fusion bonding techniques for several thermoplastic composite systems is evaluated by a comparative study based on the joints' strength and toughness results available in the literature. This work focuses on the three most promising fusion bonding techniques: Resistance welding, induction welding, and ultrasonic welding. The advantages and drawbacks for each one of these processes are discussed, as well as their suitability for several specific structural applications. In addition, several discordant aspects for each welding technique are identified and the corresponding recommendations are discussed. A compilation of analytical models for the mechanisms of heat generation and transient heat transfer modelling is also presented for each fusion bonding process in order to promote their application in numerical modelling.

Global energy demand is rapidly increasing due to population and economic growth, especially in large emerging countries, which will account for 90% of energy demand growth to 2035. Electric vehicles (EVs) play a paramount role in the electrification revolution towards the reduction of the carbon footprint. Here, we review all the major trends in Li-ion batteries technologies used in EVs. We conclude that only five types of cathodes are used and that most of the EV companies use Nickel Manganese Cobalt oxide (NMC). Most of the Li-ion batteries anodes are graphite-based. Positive and negative electrodes are reviewed in detail as well as future trends such as the effort to reduce the Cobalt content. The electrolyte is a liquid/gel flammable solvent usually containing a LiFeP6 salt. The electrolyte makes the battery and battery pack unsafe, which drives the research and development to replace the flammable liquid by a solid electrolyte.

Structural power composites stand out as a possible solution to the demands of the modern transportation system of more efficient and eco-friendly vehicles. Recent studies demonstrated the possibility to realize these components endowing high-performance composites with electrochemical properties. The aim of this paper is to present a systematic review of the recent developments on this more and more sensitive topic. Two main technologies will be covered here: (1) the integration of commercially available lithium-ion batteries in composite structures, and (2) the fabrication of carbon fiber-based multifunctional materials. The latter will be deeply analyzed, describing how the fibers and the polymeric matrices can be synergistically combined with ionic salts and cathodic materials to manufacture monolithic structural batteries. The main challenges faced by these emerging research fields are also addressed. Among them, the maximum allowable curing cycle for the embedded configuration and the realization that highly conductive structural electrolytes for the monolithic solution are noteworthy. This work also shows an overview of the multiphysics material models developed for these studies and provides a clue for a possible alternative configuration based on solid-state electrolytes.

Recently, the massification of new technologies, which has been adopted by a large majority of the world population, has accumulated a tremendous amount of data, including clinical data. This clinical data have been gathered up and interpreted by medical organizations in order to gain insights and knowledge useful for clinical decisions, drug recommendations, and better diagnoses, among many other uses. This paper highlights the enormous impacts of big data on medical stakeholders, patients, physicians, pharmaceutical and medical operators, and healthcare insurers, and also reviews the different challenges that must be taken into account to get the best benefits from all this big data and the available applications.

Purpose This paper aims to evaluate the influence of the parameters of the Fused Filament Fabrication (FFF) process on the mechanical properties and on the mass of parts printed in Polylactic Acid (PLA). In addition, the authors developed predictive models for the analysed responses. Design/methodology/approach A full Factorial type of experimental planning method was used to define the conditions for manufacturing parts according to the variation of the construction parameters, extrusion temperature and print speed. Samples were printed for tensile, flexion and compression tests. Their mass was measured. Multiple regression methods, based on power equations, were used to build the forecasting models. Findings It was found that the extrusion temperature was the parameter of greatest influence in the variation of the analysed responses, mainly because it generates behaviour patterns and indirectly demonstrates thermal/rheological characteristics of the material used. Print speed affects responses, however, with variations dependent on part geometry and printer hardware/software. It was possible to establish prediction models with low error rates in relation to the experimental values. Originality/value The study demonstrates a good relation between the use of a structured experimental planning method as the basis for the development of predictive models based on mathematical equations, the same structure of which can be used to describe different responses.

Composite structures currently used in the automotive industry must meet strict requirements for safety reasons. They need to maintain strength under varied temperatures and strain rates, including impact. It is therefore critical to fully understand the impact behaviour of composites. This work presents experimental results regarding the influence of a range of temperature and strain rates on the fracture energy in mode I, G IC , of carbon fibre reinforced plastic plates. To determine G IC as a function of temperature and strain rate, double cantilever beam specimens were tested at 20, 80 and −30℃, with strain rates of 0.2 and 11 s −1 . A complementary numerical study was performed with the aim of predicting strength using the measured values. This work has demonstrated a significant influence of the strain rate and temperature on G IC of the composite materials, with higher strain rates and lower temperatures causing a decrease in the G IC values.

Structural adhesives are increasingly being used in the aerospace and automotive industries. They allow for light weight vehicles, fuel savings, and reduced emissions. However, the environmental degradation of adhesive joints is a major setback in its wide implementation. Moisture degradation of adhesive joints includes plasticization, attacking of the interface, swelling of the adhesive and consequent creation of residual stresses. This may lead to reversible and irreversible damage. The main factors affecting the strength of adhesive joints under high and low temperatures are the degradation of the adhesive mechanical properties and the creation of residual stresses induced by different coefficients of thermal expansion (between the adhesive and the adherends). The effect of the combined effect of moisture and temperature is not yet fully understood. The aim of this study is to shed light on this subject.In this work bulk water absorption tests were conducted at different moisture conditions in order to assess the diffusion coefficient, maximum water uptake, and glass transition temperature. Aged and unaged small dogbone tensile specimens were tested under different temperature conditions. The glass transition temperature of the adhesives as a function of the water uptake was assessed. The aim is to determine the evolution of the properties of two epoxy adhesives as a function of two variables (environmental temperature and moisture).

Abstract Companies face new challenges needing to find ways to stand out from the competitors. All companies face new projects, which need to be managed assertively and faster, launching new products on the market ahead of competitors. This strategy requires enormous dexterity and agility within teams, which are increasingly multifaceted, multidisciplinary, and multifunctional. However, teams need to conciliate apparent freedom for creation with the sustainability rules, which are increasingly demanding, such as legislation and image that companies want to pass on to the market in terms of corporate social responsibility, ensuring a sustainable development of the companies. The goal of this work is to investigate and correlate agile project management and sustainability, taking into account that there are strong relationships, as well as to learn how agile project management affects organization's social, environmental, and economical dynamics from the triple bottom line standpoint. The research examines how agile project management ideas are connected to the triple bottom line concepts based on the literature. The framework was based on the theoretical assumptions underpinning the present research. The basic structure of the developed framework is based on the framework of a matrix‐based method for ordering and synthesizing data. Thus, network diagrams have been developed reproducing the links existing in the literature, both explicitly and implicitly. However, they were deeply expanded considering links not previously referred in the literature. An explanation about these new links is also provided, justifying their inclusion. Hence, the new diagrams offer a more complete landscape about how the adoption of agile practices in project management can improve sustainability in its different aspects, and vice‐versa. The findings reveal that implementing agile project management induces direct effects on an organization's social, economic, and environmental dynamics of the companies, as well as in their teams, with a favorable effect on all of them.

The article presents a literature review of electromechanical impedance spectroscopy for structural health monitoring, with emphasis in adhesively bonded joints. The concept behind electromechanical impedance spectroscopy is to use variable high-frequency structural vibrations with piezoelectric elements to monitor the local area of a structure for changes in mechanical impedance that may indicate imminent damage. Various mathematical models that correlate the structural impedance with the electric response of the piezoelectric sensors are presented. Several algorithms and metrics are introduced to detect, localize, and characterize damage when using electromechanical impedance spectroscopy. Applications of electromechanical impedance spectroscopy to study adhesive joints are described. Research and development of alternative hardware for electromechanical impedance spectroscopy is presented. The article ends by presenting future prospects and research of electromechanical impedance spectroscopy–based structural health monitoring, and, while advances have been made in algorithms for damage detection, localization, and characterization, this technology is not mature enough for real-world applications.

The difficulties in the machining of duplex stainless steel are well known. However, research on this matter is rather limited. Suppliers offer quite different cutting tools for the same raw material, with end mills of two, three or even four knives and a huge number of distinct coatings, some of them under commercial brands, making it difficult to assess the advantages they offer. Furthermore, there is a remarkable difference among the several types of duplex stainless steel available nowadays on the market. The present work intends to assess the machining performance of different tools, analyzing the behavior and wear mechanisms with two different cutting lengths, keeping constant the machining trajectory. Some other parameters were also kept constant, such as cutting speed, depth of cut and cutting width, as well as feed per tooth. The machining process was carried out under lubricated conditions, using an emulsion of 5% oil in water. Tools provided with a different number of teeth and surface coatings were tested, analyzing the wear behavior of each cutting length using scanning electron microscopy, trying to identify wear performance and how each coating contributes to increased tool life. The surfaces produced were also analyzed by means of profilometry measurements, correlating tool wear and part surface roughness. This comparative study allows determining the advantages of different tools relative to others, based on coatings and tool geometry.

Adhesive bonding is widely seen as the most optimal method for joining composite materials, bringing significant benefits over mechanical joining, such as lower weight and reduced stress concentrations. Adhesively bonded composite joints find extensive applications where cyclic fatigue loading takes place, but this might ultimately lead to crack damage and safety issues. Consequently, it has become essential to study how these structures behave under fatigue loads and identify the remaining gaps in knowledge to give insights into new possibilities. The fatigue life of adhesively bonded composite joints is influenced by various parameters, including joint configuration and material properties of adherends and adhesive. Numerous studies with varying outcomes have been documented in the literature. However, due to the multitude of influential factors, deriving conclusive insights from these studies for practical design purposes has proven to be challenging. Hence, this review aims to address this challenge by discussing different methods to enhance the fatigue performance of adhesively bonded composite joints. Additionally, it provides a comprehensive overview of the existing literature on adhesively bonded composite joints under cyclic fatigue loading, focusing on three main aspects: Adherends modification, adhesive modification, and joint configurations. Since the effect of modifying the adhesive, adherends, and joint configurations on fatigue performance has not been comprehensively studied in the literature, this review aims to fill this gap by compiling and comparing the relevant experimental data. Furthermore, this review discusses the challenges and limitations associated with the methods that can be used to monitor the initiation and propagation of fatigue cracks.

Adhesives play an important role in many key industrial sectors, such as the automotive industry, enabling the construction of lightweight, multi-material structures, combining polymers, composites and metals. However, adhesives are usually polymeric materials, which can be affected by environmental and working conditions, such as moisture and contamination. Although moisture and contamination degrade the adhesive, the failure of a bonded joint is often ultimately interfacial. Therefore, a literature review on the influence of those factors on the interfacial properties of adhesive joints is performed to understand the phenomena that take part in the degradation on adhesive joints when subjected to humid and contaminated environments, which can oftentimes be the case in factory conditions, especially for parts from third-party suppliers. The mechanisms and effects of moisture aging and contamination are presented, as well as experimental testing methods and practical case studies. It is concluded that both moisture and other contaminants may lead to a reduction in joint strength and catastrophic adhesive failure. Moisture absorption can occur through the adhesive, but in an adhesive joint, it can additionally occur through the substrate, the interface between the adhesive and the substrate or in the cracks and pores of the adhesive. After water ingresses into the adhesive, it decreases its mechanical properties and plasticizes it. However, in an adhesive joint, the water diffusion occurs much faster than in bulk adhesive due to the complementary diffusion paths, which typically leads to adhesive failure at the adhesive/substrate interface. Additionally, in an adhesive joint, water may induce the hydrolysis of the substrates or have other chemical interactions with them. Contaminants can diffuse through the joint or remain at the adhesive/ substrate interface. When they diffuse through the joint, they have consequences similar to those of water sorption. However, when they remain at the interface, they can produce locally debonded areas, which may lead to joint failure.

In this work an innovative technique for multi-material adhesive joints debonding by combining the inductive heating method and the use of thermally expandable particles (TEPs) is presented. First, single lap joints (SLJs) using various combinations of adherends (high-strength steel (HS), aluminum (Al), and carbon fiber reinforced plastics (CFRP)) were fabricated and tested to assess the influence of TEP content on the lap-shear strength of the joints. Further, the ability of the TEP-modified joints to support temperature-controlled debonding was evaluated. It was shown that the control of debonding process by temperature is possible. The temperature needed for debonding is a function of TEP content and can be lowered by increasing the TEP content. Relatively similar debonding temperatures were found for multi-material/dissimilar joints debonding compared with similar joints, but more induction heating power is generally necessary to disassemble multi-material adhesive joints.

The automotive industry is increasingly using adhesive joints bonding advanced lightweight materials to reduce vehicle weight. Strength under impact loadings is a major concern for this application and mixed adhesive joints can effectively improve the joints by combining stiffness and flexibility on the same overlap. This work introduces and studies several configurations for static and impact tests of mixed adhesive joints with four adhesives in different combinations. The main purpose of this work is the development of a strong adhesive joint using a mixed adhesive layer and perform a series of mechanical to study its mechanical behaviour. It is concluded that the use of the mixed adhesive technique improves both static and impact strength by introducing flexibility to the joint which subsequently allows more energy absorption when introduced in crash resistant structures.

It is well known that injection of glass fibre–reinforced plastics (GFRP) causes abrasive wear in moulds’ cavities and runners. Physical vapour deposition (PVD) coatings are intensively used to improve the wear resistance of different tools, also being one of the most promising ways to increase the moulds’ lifespan, mainly when used with plastics strongly reinforced with glass fibres. This work compares four different thin, hard coatings obtained using the PVD magnetron sputtering process: TiAlN, TiAlSiN, CrN/TiAlCrSiN and CrN/CrCN/DLC. The first two are monolayer coatings while the last ones are nanostructured and consist of multilayer systems. In order to carry out the corresponding tribological characterization, two different approaches were selected: A laboratorial method, using micro-abrasion wear tests based on a ball-cratering configuration, and an industrial mode, analysing the wear resistance of the coated samples when inserted in a plastic injection mould. As expected, the wear phenomena are not equivalent and the results between micro-abrasion and industrial tests are not similar due to the different means used to promote the abrasion. The best wear resistance performance in the laboratorial wear tests was attained by the TiAlN monolayer coating while the best performance in the industrial wear tests was obtained by the CrN/TiAlCrSiN nanostructured multilayer coating.

This paper presents a new approach based on Multi-Criteria Decision Analysis (MCDA), named PROMETHEE-SAPEVO-M1, through its implementation and feasibility related to the decision-making process regarding the evaluation of helicopters of attack of the Brazilian Navy. The proposed methodology aims to present an integration of ordinal evaluation into the cardinal procedure from the PROMETHEE method, enabling to perform qualitative and quantitative data and generate the criteria weights by pairwise evaluation, transparently. The modeling provides three models of preference analysis, as partial, complete, and outranking by intervals, along with an intra-criterion analysis by veto threshold, enabling the analysis of the performance of an alternative in a specific criterion. As a demonstration of the application, is carried out a case study by the PROMETHEE-SAPEVO-M1 web platform, addressing a strategic analysis of attack helicopters to be acquired by the Brazilian Navy, from the need to be evaluating multiple specifications with different levels of importance within the context problem. The modeling implementation in the case study is made in detail, first performing the alternatives in each criterion and then presenting the results by three different models of preference analysis, along with the intra-criterion analysis and a rank reversal procedure. Moreover, is realized a comparison analysis to the PROMETHEE method, exploring the main features of the PROMETHEE-SAPEVO-M1. Moreover, a section of discussion is presented, exposing some features and main points of the proposal. Therefore, this paper provides a valuable contribution to academia and society since it represents the application of an MCDA method in the state of the art, contributing to the decision-making resolution of the most diverse real problems.

Abstract The structural applications of adhesively bonded joints on transportation industries have been increasing, and it is expected that this rising trend persists in the future. The appropriate design of these joints should address two main issues: fatigue behaviour and environmental effects. Environmental effects consist of the degradation of the bonded joints by means of harmful influence of temperature, moisture or both simultaneously. These effects can have an impact on the fatigue behaviour of bonded joints because they influence the quality of the bonding. The combination of environmental effects and fatigue lead to synergetic consequences resulting in premature and unpredictable rupture, which transforms these issues into relevant and actual research topics. The present paper describes the most recent works addressing the referred subjects. Experimental works and analytical/numerical approaches are also described aiming to give a picture of the real state‐of‐the‐art. Actual limitations and perspectives of future evolution are also discussed.

PVD (physical vapor deposition) and CVD (chemical vapor deposition) have gained greater significance in the last two decades with the mandatory shift from electrodeposition processes to clean deposition processes due to environmental, public safety, and health concerns. Due to the frequent use of coatings in several industrial sectors, the importance of studying the chromium coating processes through PVD–sputtering can be realized, investing in a real alternative to electroplated hexavalent chromium, usually denominated by chromium 6, regularly applied in electrodeposition processes of optical products in the automotive industry. At an early stage, experimental tests were carried out to understand which parameters are most suitable for obtaining chromium coatings with optical properties. To study the coating in a broad way, thickness and roughness analysis of the coatings obtained using SEM and AFM, adhesion analyzes with the scratch-test and transmittance by spectrophotometry were carried out. It was possible to determine that the roughness and transmittance decreased with the increase in the number of layers, the thickness of the coating increased linearly, and the adhesion and resistance to climatic tests remained positive throughout the study. Thus, this study allows for the understanding that thin multilayered Cr coatings can be applied successfully to polymeric substrates regarding optical applications in the automotive industry.