P 1399 – Development of a methodology for evaluating the bonded joint of a steel-intense ultimaterial battery tray at mechanical and medial load in consideration of the interphase structure
One of the main requirements for the adhesive bonding of battery housing structures is to ensure tightness and corrosion resistance in the wet area of the vehicle. These requirements can be transferred to other industries with a strong SME focus, such as plant and container construction. Here, there is a great deal of uncertainty on the market as to how a reliable design method, based on experimental tests of a corresponding steel bonded joint, as well as its verification and quality assurance, can look. Elaborate tests on real components are challenging, especially for SMEs, due to the high financial costs involved. For this reason, the research institutions have developed an applicationoriented and fundamentally scientifically validated method to predict the long-term behavior of the steel bonded joint under the given requirements. To this end, materialadhesive ombinations relevant for use in battery housings were first selected. Then, operationally relevant corrosive loads for bonded joints were set, and requirements for the tightness of bonded joints were researched. Afterward, the long-term resistance of the adhesive system to the defined rapid aging tests was determined on the basis of adhesive substance samples. Subsequently, the influence of the load on steel-intensive mixed joints was identified, and a test rig was developed, which enables a leak test under superimposed mechanical load. The results of the leak test were correlated with the structure of the adhesive/metal interphase and its load-dependent degradation behavior. From the knowledge gained, a test methodology for determining the resistance was developed in addition to a model for the damage mechanism. These findings primarily serve SMEs for the long-term resistant design of bonded joints.
To validate the method, a sample geometry similar to that of a component was developed, which was used to verify the transferability of the test method to more complex components.
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T. Schmolke, Prof. Dr.-Ing. G. Meschut, P. Vieth, Dr. D. Meinderink, Prof. Dr.-Ing. G. Grundmeier