@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{58438, abstract = {{This study presents a numerical approach using a 3D finite element model to quantify the remaining clamp load of a plastic nut joint after a specific time. The viscoelastic relaxation of a thermoplastic nut, which is predominantly screwed on a welding stud, is described by a material card using Prony Series. Prony Series are derived from experimental dynamical mechanical analysis with different moisture and fiber contents of the thermoplastic. Since plastic nuts usually do not have preformed threads, the increased temperatures and resulting stresses from the thread-forming process are considered in the simulation. An FE model is created and verified by substrate stress relaxation tests. Experimental clamp load measurements with miniature compression load cells verify the clamp load prediction and show a good agreement. The developed model is used to analyze the clamp load distribution within the threads and reveals an almost even distribution within the threads.}}, author = {{Wippermann, Jan and Meschut, Gerson}}, issn = {{0043-2288}}, journal = {{Welding in the World}}, publisher = {{Springer Science and Business Media LLC}}, title = {{{Numerical modeling of clamp load relaxation of plastic nuts under varying moisture and fiber contents}}}, doi = {{10.1007/s40194-025-01928-4}}, year = {{2025}}, } @article{58444, author = {{Wippermann, Jan and Meschut, Gerson}}, journal = {{JOINING PLASTICS}}, title = {{{Entwicklung einer Methode für die Prognose des Anziehdrehmoments von Kunststoffmutte}}}, year = {{2025}}, } @inbook{58457, abstract = {{Die Transformation der bisher linearen Wirtschaft zu einer Kreislaufwirtschaft und einer möglichst emissionsneutralen Herstellung und Verwendung von Produkten bedarf einer ganzheitlichen Forschung und Entwicklung in allen Bereichen der Prozesskette. Die Fügetechnik gilt dabei als Enabler moderner Hybridstrukturen und ermöglicht die anforderungsgerechte Verbindung artverschiedener Werkstoffe mit unterschiedlichen technisch-wirtschaftlichen Eigenschaftsprofilen. Aktuelle Herausforderungen umfassen das qualitätsgesicherte Fügen bei einer zunehmenden Materialvielfalt aus Primär- und Sekundärwerkstoffen sowie das gezielte Entfügen von Leichtbaustrukturen in Instandsetzungs- oder Recyclingprozessen. Ein weiterer Entwicklungsschwerpunkt liegt auf der menschzentrierten Ausrichtung von Arbeitsprozessen. So können Arbeitskräfte durch eine ergonomische Produktions- und Fügeprozessplanung sowie die Entwicklung und Einbindung prozessbegleitender Mixed-Reality-Technologien gezielt entlastet und dem derzeit zu verzeichnenden Fachkräftemangel effektiv begegnet werden. Das vorliegende Whitepaper zeigt aktuelle Herausforderungen in der Fügetechnik auf, fasst relevante Erkenntnisse und Lösungsansätze aus Industrie und Forschung sowie dem Verbundforschungsvorhaben „Konzepte für die ressourceneffiziente und sichere Produktion von Leichtbaustrukturen“ (KORESIL) zusammen und leitet geeignete Handlungsempfehlungen für die Industrie ab. Diese sollen beteiligten Anwendern strategische Ansätze aufzeigen, um Prozesse ressourceneffizienter und nachhaltiger gestalten zu können.}}, author = {{Meschut, Gerson and Gilich, Julian and Chudalla, Nick Andre}}, booktitle = {{Komplexität beherrschen, Kreisläufe schließen : Soziotechnische Systeme für ressourceneffiziente Leichtbaustrukturen ; Das interaktive Whitepaper}}, publisher = {{Technische Universität Dresden}}, title = {{{Ressourceneffiziente Füge- und Entfügetechnologien: Online-Content zum interaktiven Whitepaper KORESIL}}}, doi = {{10.25368/2024.53}}, year = {{2025}}, } @article{58454, abstract = {{Powertrain concepts incorporating renewable energies are an essential element of the energy revolution and increasingly require efficient manufacturing processes for electronic systems. Particularly, the joining of structures to be thermally coupled, such as the battery modules and the thermal management system (TMS), poses new challenges in process design. Factors that limit the process include the increased density, viscosity, and abrasiveness of thermal pastes as well as the pressure sensitivity of battery modules. The research presented aims to systematically investigate the influences of joining parameters on flow behavior, the formation of air inclusions, and the occurring joining forces to understand and systematically optimize the joining process. Employing a test setup following the Closing-Hele-Shaw-Cell, the influence of specific process parameters on the joining process such as the joining speed, joining gap, application pattern, and temperature was investigated for a silicone- and a polyurethane-based thermally conductive paste. The results indicate a high dependency of both the ensuing joining forces and the flow behavior on the parameters investigated. These insights imply a potential systematic parameter optimization and the specific adaptation of the joining process to improve flow behavior and reduce compressive stresses. This can ensure lower component deformations and qualify the process for the employment of cell types with a higher power density, a reduced encapsulation, and lower stiffness while at the same time improving production rates.}}, author = {{Gilich, Julian and Teutenberg, Dominik and Meschut, Gerson and Gröger, B. and Wiebicke, F. and Koch, I. and Gude, M.}}, issn = {{0043-2288}}, journal = {{Welding in the World}}, publisher = {{Springer Science and Business Media LLC}}, title = {{{Effects of various process parameters in the joining process on the squeeze flow of highly viscous thermal interface materials}}}, doi = {{10.1007/s40194-025-01929-3}}, year = {{2025}}, } @book{58456, abstract = {{Im Rahmen des BMBF-Forschungsvorhabens KORESIL wurden entlang einer beispielgebenden Prozesskette für hybride Leichtbaustrukturen notwendige Forschungs- und Entwicklungsschwerpunkte ermittelt. Insbesondere die Steigerung der Ressourceneffizienz und die Unterstützung des Menschen im Kontext zukünftiger Arbeitsumfelder standen dabei im Mittelpunkt der Arbeiten. Hierauf aufbauend konnten Handlungsempfehlungen für Wirtschaft, Wissenschaft und Politik abgeleitet werden. Das Projekt KORESIL ist eingebettet in das Projektnetzwerk des Forschungs- und Technologiezentrums für ressourceneffiziente Leichtbaustrukturen – FOREL. Dieses Zentrum wurde im Jahr 2013 als BMBF-Leuchtturmprojekt eingerichtet und ist eine offene, unabhängige Plattform zur Entwicklung von Hightech-Leichtbausystemlösungen in Multi-Material-Design für die Mobilität der Zukunft. Ziel der Plattform ist die Unterstützung von Entwicklungsprojekten, die Vernetzung der Leichtbauforschung innerhalb Deutschlands und die Zusammenführung verschiedener Förderinitiativen.}}, editor = {{Gude, Maik and Tekkaya, Erman and Zäh, Michael F. and Meschut, Gerson and Lieberwirth, Holger}}, publisher = {{Technische Universität Dresden}}, title = {{{Komplexität beherrschen, Kreisläufe schließen: Soziotechnische Systeme für ressourceneffiziente Leichtbaustrukturen ; Das interaktive Whitepaper}}}, doi = {{10.25368/2024.8}}, year = {{2025}}, } @article{58495, abstract = {{ To reduce CO2 emissions, the industry, particularly in the mobility sector, focuses on lightweight vehicles with multi-material structures. As thermal joining processes are reaching their limits, mechanical techniques such as self-piercing riveting are being used. One innovative solution is the versatile self-piercing riveting process (V-SPR), which combines different material combinations with a multi-range rivet. 1 The joining process is divided into the piercing process and the forming process of the rivet head to the respective sheet thickness. The rivet shaft requires sufficient strength to punch through the punch-sided sheet, and sufficient ductility of the rivet head is required to form onto the punch-sided sheet. To achieve a combination of these requirements, local inductive heat treatment strategies are used for the rivet. To ensure reproducible rivet hardening, a specialised device has been developed for precise rivet positioning in the induction coil and the subsequent quenching process. The heat treatment differs in terms of hardening times and temperatures. In addition, the heat treatment is combined with a subsequent tempering process. The study aims to determine the resulting hardness distributions and microstructures of the rivet and to investigate the influence of different heat treatment strategies on joint formation and load-bearing capacities. The results show that a graded hardening profile has a positive effect on the spreading behaviour of the rivet foot and the forming behaviour of the rivet head. Furthermore, the load-bearing behaviour of the joints is increased. }}, author = {{Holtkamp, Pia Katharina and Kappe, Fabian and Probst, Paula and Bobbert, Mathias 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 = {{{Investigation of local heat treatment strategies for a multi-range capable rivet and the influence on joint formation and load-bearing capacity}}}, doi = {{10.1177/14644207241307508}}, year = {{2025}}, }