@inproceedings{64131, author = {{Hermelingmeier, Lucas and Teutenberg, Dominik and Meschut, Gerson and Korten, Matthias and Urban, Peter and Marquardt, Raphael and Rethmeier, Michael}}, location = {{Köln}}, title = {{{Konzeptentwicklung für eine stahlintenisve zirkuläre und modulare Bauweise elektrisch angetriebener Fahrzeuge}}}, year = {{2026}}, } @article{63607, author = {{Striewe, Marius and Schmelzle, Lars and Possart, Gunnar and Meschut, Gerson and Mergheim, Julia and Teutenberg, Dominik}}, issn = {{0169-4243}}, journal = {{Journal of Adhesion Science and Technology}}, pages = {{1--38}}, publisher = {{Informa UK Limited}}, title = {{{Analytical parameter identification for a viscoplastic material model for structural adhesive bonds}}}, doi = {{10.1080/01694243.2025.2611999}}, year = {{2026}}, } @article{63821, author = {{Gude, Maik and Meschut, Gerson and Flügge, Wilko and Fröck, Linda and Wald, Christopher and Neßlinger, Vanessa and Dobrindt-Tittmann, Karsten and Troschitz, Juliane and Neubert, Fynn Lucas and Hofmann, Martin and Ostwald, Richard and Mathiszik, Christian and Schmale, Hans Christian and Wallmersperger, Thomas and Grundmeier, Guido}}, issn = {{0143-7496}}, journal = {{International Journal of Adhesion and Adhesives}}, publisher = {{Elsevier BV}}, title = {{{Corrosion of adhesively bonded alloys in maritime environments: A review}}}, doi = {{10.1016/j.ijadhadh.2026.104264}}, volume = {{147}}, year = {{2026}}, } @inproceedings{64130, author = {{Hermelingmeier, Lucas and Teutenberg, Dominik and Meschut, Gerson}}, booktitle = {{26. Kolloquium: Gemeinsame Forschung in der Klebtechnik}}, location = {{Köln}}, title = {{{Methodenentwicklung zur Ermittlung lokaler Klebschichtzustände innerhalb struktureller Verbindungen}}}, year = {{2026}}, } @inproceedings{64589, author = {{Rodschei, Maxim and Mergheim, Julia and Neubert, Fynn Lucas and Teutenberg, Dominik and Meschut, Gerson}}, booktitle = {{26. Kolloquium: Gemeinsame Forschung in der Klebtechnik}}, location = {{Köln}}, title = {{{Experimentelle und numerische Untersuchungen zur Alterung von Klebverbindungen unter zyklischer und hygrothermischer Beanspruchung im Stahl- und Anlagenbau}}}, year = {{2026}}, } @inproceedings{64590, author = {{Neubert, Fynn Lucas and Teutenberg, Dominik and Meschut, Gerson}}, booktitle = {{26. Kolloquium: Gemeinsame Forschung in der Klebtechnik}}, location = {{Köln}}, title = {{{Optimierung der induktiven Klebstoff-Schnellhärtung durch numerische Prozesssimulation}}}, year = {{2026}}, } @inproceedings{64593, author = {{Neubert, Fynn Lucas and Teutenberg, Dominik and Meschut, Gerson and Rodschei, Maxim and Mergheim, Julia}}, booktitle = {{DECHEMA-Workshop für Klebstoffanwender: Langzeitverhalten von Klebungen}}, location = {{Köln}}, title = {{{Bewitterung in der Simulation}}}, year = {{2026}}, } @article{64678, abstract = {{One of the major topics in the modern automotive industry is reducing emissions and increasing the mileage range. To tackle this challenge, on the one hand, modifying the powertrain system is a possibility, and on the other hand, lightweight design offers various possibilities. Multi-Material Design (MMD) involves designing car bodies that combine different materials that require joining. Given the variety of materials, mechanical joining processes are preferred. Especially the current development of the Giga/Mega-casting process concerning aluminium casting and the subsequent mechanical joining illustrates the challenges of this material group. In car production, aluminium castings are mainly made from aluminium-silicon (AlSi) alloys. Ultimately, the alloy system's insufficient ductility leads to crack initiation during mechanical joining. Cast parts are therefore often used in areas of the car body that are exposed to high-pressure loads. For example, self-piercing riveting (SPR) is used due to its high load-bearing capacity. In this study, improved joinability is demonstrated by influencing the microstructure through tailored solidification rates and a developed heat-treatment chain strategy adapted for hypoeutectic AlSi systems. Data on microstructure, mechanical, and joining properties are used to develop a solidification-joining correlation for the SPR process across a range of Si contents and solidification rates. The purpose is to develop the ability to produce suitable aluminium castings with sufficient joinability, thereby improving versatility.}}, author = {{Neuser, Moritz and Kaimann, Pia Katharina and Stratmann, Ina and Bobbert, Mathias and Klöckner, Johann Moritz Benedikt and Mann, Moritz and Hoyer, Kay-Peter and Meschut, Gerson and Schaper, Mirko}}, journal = {{Journal of Manufacturing Processes}}, keywords = {{Mechanical joining, Aluminium, Self-piercing riveting, Casting, Microstructure, Joinability AlSi-alloys}}, publisher = {{Elsevier}}, title = {{{Solidification-joinability correlation of hypoeutectic aluminium casting alloys for self-piercing riveting (SPR)}}}, doi = {{https://doi.org/10.1016/j.jmapro.2026.02.040}}, volume = {{164}}, year = {{2026}}, } @article{64813, abstract = {{This paper describes the development of a method concept for the mechanical characterisation of cathodic electrodeposition (CED) coatings in the context of adhesively bonded joints. The objective is to determine mechanical properties of coating layer in order to incorporate its influence into numerical simulation models for load-bearing adhesive joints. For this purpose, both single-lap joints (SLJ) and modified thick adherend shear specimens (TASS) with defined CED coating layers were produced and tested under quasi-static loading conditions. Additionally, the deposition process was analysed in terms of coating thickness evolution as a function of deposition time and applied voltage. The specimens were pre-cured to reduce gas inclusions from evaporating solvents in the CED coating layer. The pre-curing temperature was determined using DSC. The results indicate that the modified TASS configuration is particularly suited for the reproducible evaluation of the shear load-bearing capacity. In comparison to the SLJ, it favours the degassing of solvents through the installation of grooves. Furthermore, it is demonstrated that gas-induced defect zones originating from the electrochemical deposition process significantly compromise joint performance. The experimental and process methodology developed in this study enables isolated characterisation of the coating layer and provides a solid foundation for simulation of coated adhesive joints.}}, author = {{Hofmann, Julia and Teutenberg, Dominik and Meschut, Gerson}}, issn = {{0021-8464}}, journal = {{The Journal of Adhesion}}, pages = {{1--16}}, publisher = {{Informa UK Limited}}, title = {{{Method development for the mechanical characterisation of cathodic electrodeposition coatings for numerical simulation of bonded joints}}}, doi = {{10.1080/00218464.2026.2621198}}, year = {{2026}}, } @inproceedings{64815, author = {{Hofmann, Julia and Teutenberg, Dominik and Meschut, Gerson and Schulz, Paul and Gude, Maik}}, booktitle = {{26. Kolloquium: Gemeinsame Forschung in der Klebtechnik}}, title = {{{Entwicklung eines methodischen Ansatzes zur Gewährleistung der anforderungsgerechten Klebbarkeit von rezyklatbasierten Kunststoffen in der Kreislaufwirtschaft}}}, year = {{2026}}, } @inproceedings{64814, author = {{Hofmann, Julia and Teutenberg, Dominik and Meschut, Gerson}}, booktitle = {{26. Kolloquium: Gemeinsame Forschung in der Klebtechnik}}, title = {{{Methodenentwicklung zur numerischen Auslegung von Klebverbindungen mit lackierten Fügeteilen}}}, year = {{2026}}, } @article{63391, abstract = {{This study addresses the challenge of insufficient weld penetration in the outer thin low-carbon steel during resistance spot welding of three-layer dissimilar stack-ups containing advanced high-strength steels. To overcome thermal imbalance constraints, an innovative strategy leveraging plastic shell containment is proposed to elevate the expulsion-free heat input threshold. By applying a combined preheating and ramping current profile, a coordinated “shell-first, nugget-second” sequence is achieved. This mechanism creates a solid-state barrier prior to rapid fusion, effectively preventing expulsion. Experimental results demonstrate that while the reference constant-current schedule fails to maintain a process window under a 2 mm initial gap (IG) disturbance, the proposed strategy significantly enhances process stability. It increases the maximum expulsion-free heat input by 24 % (to 6338 J) under normal conditions and by 77 % (to 6482 J) under the IG condition. Crucially, the increased heat input drives nugget growth across all interfaces, achieving a penetration depth of 0.38 mm (48 % penetration ratio) in the low-carbon steel sheet under the gap condition. These findings validate the strategy’s effectiveness in ensuring weld quality and robustness, which is further confirmed by its transferability to a lowerresistivity DX54D cover sheet.}}, author = {{Yang, Keke and Männer, Leonhard and Wang, Zhuoqun and Olfert, Viktoria and Böhm, Yannic and Hein, David and Meschut, Gerson}}, issn = {{1526-6125}}, journal = {{Journal of Manufacturing Processes}}, number = {{Special issue entitled: ‘Trends on spot joining’ published in Journal of Manufacturing Processes.}}, pages = {{984--1000}}, publisher = {{Elsevier BV}}, title = {{{Process window expansion with transferable applicability in three-layer dissimilar steel resistance spot welding via expulsion prevention}}}, doi = {{10.1016/j.jmapro.2025.12.036}}, volume = {{157}}, year = {{2026}}, } @article{63418, abstract = {{Manufacturing tolerances have a measurable influence on the structural integrity of self-piercing riveted (SPR) joints in automotive applications, yet their quantitative impact on load-bearing behavior remains insufficiently resolved. This study establishes a validated hierarchical methodology to predict tolerance-dependent failure behavior of SPR joints, progressing from coupon to sub-component scale through an integrated experimental–numerical approach. Five critical manufacturing tolerances, including rivet length (±0.5 mm), rivet head position (±0.3 mm), orthogonality deviation (2.8° and 5°), lateral offset (up to 1.2 mm), and flange overlap reduction (up to 7.5 mm), were investigated. Steel–steel joints exhibited a higher sensitivity to tolerances by a factor of 2–3 compared to steel–aluminum joints. A unified effective rivet length concept was developed to consolidate the geometric effects of all tolerances into a single physically meaningful parameter, enabling load-bearing capacity prediction with R2 > 0.95 across all evaluated loading directions. The sub-component validation employing T-joint specimens indicates a 2–3 fold amplification of tolerance effects at critical structural regions, providing experimental evidence for the hierarchical scaling principle. The methodology was implemented in a tolerance-dependent CONSTRAINED_SPR3 formulation, providing >99 % computational efficiency improvement while maintaining a deviation in maximum force prediction within ±7 %. This framework enables the physically consistent representation of manufacturing variation within large-scale simulations and establishes a transferable basis for tolerance-resilient virtual vehicle development.}}, author = {{Olfert, Viktoria and Yang, Keke and Rochel, Philip and Bähr, Philipp and Hein, David and Sommer, Silke and Meschut, Gerson}}, issn = {{1526-6125}}, journal = {{Journal of Manufacturing Processes}}, number = {{Special issue entitled: ‘Trends on spot joining’ published in Journal of Manufacturing Processes.}}, pages = {{1250--1273}}, publisher = {{Elsevier BV}}, title = {{{Predictive modeling of tolerance-dependent failure behavior of self-pierce riveted joints: From coupon-level tests to sub-component validation}}}, doi = {{10.1016/j.jmapro.2025.12.058}}, volume = {{157}}, year = {{2026}}, } @article{65104, author = {{Hermelingmeier, Lucas and Beule, Felix and Teutenberg, Dominik and Meschut, Gerson}}, issn = {{0143-7496}}, journal = {{International Journal of Adhesion and Adhesives}}, publisher = {{Elsevier BV}}, title = {{{Comparison of fixture-based and manual fiber integration in adhesive joints: Effects on strain signal quality}}}, doi = {{10.1016/j.ijadhadh.2026.104319}}, volume = {{149}}, year = {{2026}}, } @article{65373, abstract = {{To reduce CO₂ emissions, the automotive industry is adopting multi-material structures. Fusion-based joining reaches its limits for aluminium–steel due to brittle intermetallic phases and mismatched thermophysical properties; therefore, mechanical joining (e.g., SPR) is used. Though conventional SPR requires tool changes for different stack-ups. Versatile self-piercing riveting (V-SPR) addresses this with an extended punch actuator and a multi-range-capable rivet (Kappe in PERD16:363–378, 2022), enabling joints up to 600 MPa across varying thicknesses without retooling. With the use of ultra-high-strength steels up to 1000 MPa, optimisation is required. This study quantifies how rivet shank geometry affects joint formation using a design of experiments and validated 2D axisymmetric FE simulations. The optimum depends strongly on the material system. For CP1000–EN AW-6014, maximum interlock f is predicted for a medium shank thickness of about 0.73 mm, a small internal foot radius of 0.620 mm, and a deeper drill depth of 3.136 mm, yielding f fc =0.4503 mm with a desirability of 0.954. For EN AW-6014–EN AW-6014, the optimum shifts to a thinner shank of 0.670 mm, a larger internal foot radius of 0.820 mm and a shallow drill depth of 2.30 mm, giving ffc = 0.3023 mm with a desirability of 1.0. A compromise geometry of 0.713 mm shank thickness, 0.776 mm internal foot radius and 2.755 mm drill depth achieves ffc = 0.3641 mm for CP1000–aluminium and ffc = 0.1851 mm for aluminium–aluminium with an overall desirability D = 0.6378, expanding V-SPR to ultra-high-strength steel–aluminium joints while maintaining aluminium joinability.}}, author = {{Kaimann, Pia Katharina and Ritter, Nico and Bobbert, Mathias and Meschut, Gerson}}, issn = {{2731-6564}}, journal = {{Discover Mechanical Engineering}}, number = {{1}}, publisher = {{Springer Science and Business Media LLC}}, title = {{{Influence of the shank geometry on the joint formation of the versatile self-piercing riveting of ultra-high-strength steel-aluminium and aluminium-aluminium assemblies}}}, doi = {{10.1007/s44245-026-00221-y}}, volume = {{5}}, year = {{2026}}, } @article{65668, author = {{Damm, Jannis and Ummenhofer, Thomas and Albiez, Matthias and Meschut, Gerson and Sander, Sascha and Teutenberg, Dominik and Kötz, Fabian}}, issn = {{0021-8464}}, journal = {{The Journal of Adhesion}}, pages = {{1--39}}, publisher = {{Informa UK Limited}}, title = {{{Life prediction of adhesive steel joints under ageing stress – experimentally based model validation}}}, doi = {{10.1080/00218464.2026.2671924}}, year = {{2026}}, } @article{65673, abstract = {{Subject of this paper is the investigation of the influence of local joint kinematics on the load-bearing and failure behavior of self- piercing riveted (SPR) joints. It can be shown that the local joint kinematics of SPR joints correlate with the failure mechanism of the joint. The kinematics are highly influenced by the material properties of the joining partners. Detailed experimental results from tensile tests on a representative SPR joint are presented, with local joint kinematics quantified using multiple complementary measurement methods (optical measurement, micrographs, in situ computer tomography). Furthermore, results of component tests are shown where the kinematics of the joints have been measured in the same manner. The experimental results are later used to calibrate simulation models for crash application which are used to simulate the specimen and component tests. The results of the investigation show that the local joint kinematic influences the failure behavior of the joint. Simulations of the experimental tests have shown good results, and the investigated models are able to predict the actual joint behavior.}}, author = {{Bähr, Philipp and Striewe, Marius and Dargel, Alrik and Sommer, Silke and Hein, David and Meschut, Gerson}}, issn = {{1464-4207}}, journal = {{Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications}}, publisher = {{SAGE Publications}}, title = {{{Experimental investigation of local joining element kinematics in mechanical joints and surrogate modelling for crash applications}}}, doi = {{10.1177/14644207261420657}}, year = {{2026}}, } @article{65615, abstract = {{Self-piercing riveting (SPR) is a well-established joining technique in lightweight construction, as it enables the joining of different materials without requiring pre-drilling. However, the necessary adaptation of the rivet-die combination to the respective material and thickness combinations requires a large number of specific tool sets, which significantly limits the process's flexibility. To overcome these limitations, the versatile self-piercing riveting (V-SPR) was developed, which features enhanced punch actuation in combination with a multi-range-capable rivet . In this context, the concept of a movable die was introduced, which enables an extended process window and adaptable joint formation. Kappe et al. presented initial studies demonstrating the potential of this approach . However, a detailed numerical understanding of the underlying mechanisms remains lacking. This paper presents a numerical analysis of V-SPR with a movable die using a finite element (FE) model. The model includes deformable rivets, sheet metal materials and a kinematically controlled die with adjustable movement. A parameter study was conducted to analyse the influence of die movement on the material flow of the rivet and sheets, as well as joint formation. The simulations were validated using selected experimental data. The goal is to compare the joint geometries achieved with fixed and moving dies and expand the process windows of VSPR. The results demonstrate that the movable-die concept significantly enhances the material flow of both the sheets and the rivet, resulting in a noticeably larger and more reliable interlock than what is achievable with V-SPR using a fixed die. The numerical analyses support the observations reported by Kappe et al. and extend them by providing a quantitative description of how die displacement influences the resulting interlock size. Moreover, the ability to precisely control the die movement makes it possible to join challenging sheet-metal combinations that are difficult to process with conventional setups, particularly in cases involving thicker sheet materials.}}, author = {{Kaimann, Pia Katharina and Bobbert, Mathias and Meschut, Gerson}}, issn = {{1662-9752}}, journal = {{Materials Science Forum}}, pages = {{149--160}}, publisher = {{Trans Tech Publications, Ltd.}}, title = {{{Numerical Analysis of the Influence of a Movable Die on Joint Formation in Versatile Self-Piercing Riveting}}}, doi = {{10.4028/p-8jkha8}}, volume = {{1185}}, year = {{2026}}, } @inbook{65689, abstract = {{The use of aluminium materials in the structural and bodywork areas of assemblies has proven to be a targeted option for lightweight design. How-ever, the reliable and cost-efficient joining of aluminium components remains a challenge. Mechanical joining methods, such as riveting, are frequently used in the automotive and aerospace construction industries. Rivets are made from heat-treated steels. Compared to steel, the use of aluminium materials for fasten-ers offers several advantages in terms of joining properties, particularly in terms of recyclability, corrosion resistance and reduced weight of the joined structure. Additionally, the manufacturing process is shorter since aluminium fasteners do not require coating. However, aluminium rivets can often not be used due to the insufficient mechanical strength of the fastener material in relation to the joining component materials. This study systematically investigates the requirements for using solid alu-minium self-piercing rivets. The influence of rivet geometry adjustments on the joint quality is analysed using numerical simulation. The results are used to derive and evaluate an optimised rivet geometry for joining pure aluminium sheets. On this basis, solid self-drilling rivets with optimised geometry are manufactured from particle-reinforced aluminium produced in a continuous extrusion process by machining. The integration of particles increases the material’s strength. Exper-imental tests are conducted to evaluate the use of optimised solid self-piercing rivets. The quality-relevant parameters are determined and evaluated based on macrographs of the joints.}}, author = {{Koch, Steffen and Weber, Joshua and Meschut, Gerson and Stadelmann, Claudia and Böhm, Wolfgang and Merklein, Marion}}, booktitle = {{Proceedings in Engineering Mechanics}}, isbn = {{9783032236401}}, issn = {{2731-0221}}, keywords = {{Solid self-piercing riveting cdot particle-reinforced aluminium cdot continuous powder extrusion cdot Joining technology cdot Rivet geometry cdot lightweight design}}, location = {{Coimbra}}, publisher = {{Springer Nature Switzerland}}, title = {{{Particle-Reinforced Aluminium Solid Self-piercing Rivets for Joining Aluminium Alloy Sheets}}}, doi = {{10.1007/978-3-032-23641-8_1}}, year = {{2026}}, } @article{66541, abstract = {{Expulsion in resistance spot welding (RSW) causes weld quality fluctuations and increases quality-control effort in high-volume manufacturing. Existing data-driven studies have mainly addressed post-occurrence expulsion detection, process-end classification, or the identification of influencing factors, whereas online monitoring requires short-term risk estimation before the event occurs. In this study, expulsion prediction is formulated as a sliding-window-based pre-expulsion risk estimation task for the currently welded spot. A physics-guided hybrid GRU-XGBoost ensemble is developed to combine temporal learning from dynamic resistance and electrode-force signals with process-physics-related scalar features describing heat input, resistance state, and force response. The framework was evaluated on 2730 valid welds, including 588 expulsion and 2142 non-expulsion welds, using weld-grouped five-fold cross-validation with fold-level working-point selection. The ensemble achieved an area under the ROC curve of 0.945 ± 0.004 and a weld-level recall of 90.6 ± 3.7% at an average false alarm rate of 9.8 ± 0.2%, outperforming both individual branches. For the 533 correctly warned expulsion welds, the median early-warning lead time was 56 ms. These results indicate that online, physically interpretable pre-expulsion risk prediction is feasible under low-false-alarm constraints within the investigated RSW configuration and provide a basis for future adaptive monitoring and control studies.}}, author = {{Yang, Keke and Li, Chong and Beck, Robert and Hein, David and Meschut, Gerson}}, issn = {{1526-6125}}, journal = {{Journal of Manufacturing Processes}}, keywords = {{Resistance spot welding, Expulsion prediction, Physics-guided machine learning, Hybrid ensemble modelling, Process monitoring}}, pages = {{135--153}}, publisher = {{Elsevier BV}}, title = {{{A physics-guided hybrid framework for online pre-expulsion prediction in resistance spot welding}}}, doi = {{10.1016/j.jmapro.2026.07.042}}, volume = {{174}}, year = {{2026}}, }