@article{63616, 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 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{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{63665, 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 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}}, } @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{64916, abstract = {{The joining of dissimilar materials, such as steel and aluminum, entails significant challenges during thermal curing processes due to differing coefficients of thermal expansion. This study addresses the formation of “viscous fingering” instabilities in structural adhesive joints, which are induced by thermally driven relative displacements during the liquid phase of the adhesive. Using a component-like specimen “bridge specimen,” the dependency of this phenomenon on process temperature and structural stiffness (rivet distance) was characterized. Experimental results reveal that while the relative displacement scales cubically with the free buckling length, the resulting adhesive area reduction follows an exponential trend, leading to a loss of effective bond area of up to 79%, which significantly compromises the joint strength in automotive applications. To predict these process-induced defects, a thermo-chemo-viscoelastic-viscoplastic adhesive model implemented in LS-DYNA was applied. The model combines curing kinetics, viscoelastic relaxation, and pressure-dependent plasticity and features a geometric damage parameter (D) that captures the adhesive area reduction caused by viscous fingering as an exponential function of the accumulated normal strain in the liquid phase. This damage parameter, calibrated on base-specimen level, was transferred to the component geometry. The simulation demonstrated high predictive accuracy with a maximum deviation of the adhesive area reduction of 3.1% compared to experimental data. This validates the model’s capability to predict manufacturing-induced damage in complex hybrid structures solely based on thermal boundary conditions.}}, author = {{Al Trjman, Mohamad and Beule, Felix and Teutenberg, Dominik and Meschut, Gerson and Riese, Julia}}, issn = {{0021-8464}}, journal = {{The Journal of Adhesion}}, keywords = {{Adhesive area reduction, CED coating process, delta alpha problem, epoxy structural adhesive, influence of manufacture, multi-material design, numerical simulation (FEM), relative displacements, viscous fingering (saffman-taylor-instability).}}, pages = {{1--24}}, publisher = {{Informa UK Limited}}, title = {{{Experimental characterization and numerical analysis of the influence of the CED coating process on viscous fingering formation in hybrid-jointed mixed structures}}}, doi = {{10.1080/00218464.2026.2644394}}, year = {{2026}}, } @article{64985, abstract = {{Modern industrial development has necessitated a wide range of joining technologies. Self-pierce riveting has become a prevalent technique for sheet metal assembly, especially in automotive applications. Achieving proper joint geometry and adequate load-bearing capacity depends on appropriate tool selection and precise process control. Material properties and condition also play a significant role in process performance. To accommodate the inevitable variations in component characteristics during production, a robust and stable joining process is essential. The study focuses on investigating the influence of preformed joining partners on the joining process and the joint's load capacity. An EN AW-6014 in T4 condition, as well as an HCT590X, are used as materials for this study. For this purpose, an exemplary process chain consisting of the steps of performing, joining, and shear load testing is studied. Each process step is implemented using an FE model to predict the outcome of subsequent steps. For analysis of the influence of pre-strain, an optimisation software is used to plan and execute variations of the process. These variations are used to create a meta-model that can describe the relationships between pre-forming and characteristic parameters of subsequent process steps. The resulting model is validated by comparing simulation and experimental data. Finally, in a novel approach, the robustness of the presented process chain is analyzed in terms of a tolerable performance level for the joining partners.}}, author = {{Ludwig, Jean-Patrick and Tolke, Emil and Schlichter, Malte Christian and Bobbert, Mathias and Meschut, Gerson}}, issn = {{2666-3309}}, journal = {{Journal of Advanced Joining Processes}}, keywords = {{Self-pierce riveting, FE modelling, Plastic pre-deformation, Meta modelling}}, publisher = {{Elsevier BV}}, title = {{{Numerical analysis of the robustness of self-pierce riveting with pre-formed joining partners}}}, doi = {{10.1016/j.jajp.2026.100391}}, volume = {{13}}, 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{58444, author = {{Wippermann, Jan and Meschut, Gerson}}, journal = {{JOINING PLASTICS}}, title = {{{Entwicklung einer Methode für die Prognose des Anziehdrehmoments von Kunststoffmutte}}}, year = {{2025}}, }