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INVESTIGATION INTO THE INFLUENCE OF SURFACE TOPOGRAPHY
(ROUGHNESS / WAVINESS) ON THE ADHESION OF ENGINEERING
MATERIALS
Mohd Faizi*1
*1Student, Department Of Mechanical Engineering, National Institute Of Technology Calicut,
Calicut, Kerala, India.
ABSTRACT
The adhesion based joining technology offers many advantages compared to other methods of joining and its
usage is increasing for manufacturing and assembly. Surface roughness is believed to be one important
parameter that controls the state of adhesion strength. This work aims to investigate the influence of
roughness, and waviness on the adhesive joint of two engineering materials, aluminium, low carbon steel using
stylus instrument. Influence of roughness and waviness is investigated by 2D roughness parameters measured
from a specimen of with using aluminium and low carbon steel. Several specimens with different surface
topographies were prepared by means of the different manufacturing process such as polishing, milling, and
surface grinding, for the investigation. Shear strength of adhesive joint, as adhesive strength indicators, is
measured by means of the tensile testing machine. Epoxy-based structural adhesive (Araldite) is applied in
uniform thickness on the specimens with different surface topographies. The experiments are conducted as per
ASTM D 1002 standard meant for performance studies of adhesive joint. The experiments indicate that the
shear strength of adhesive joints increases with an increase in roughness of specimen. A rougher surface has
better adhesion because the area between substrate and coating is increased. The work presents optimal values
of surface topographies parameter for a better adhesive joint based on experimental evidence.
Keywords: Adhesive Thickness, Lap Shear Strength, Surface Roughness, Waviness, Mild Steel, Aluminium.
I. INTRODUCTION
The importance of adhesive material joining technology is increasing in the field of design and manufacturing
because it has several advantages compared with other methods, like rivet joint and welded joint compare to
these types of joint adhesive lap joints is better because of less joint weight. During failure in rivet and welded
joint whole workpiece will be scrape, but in the adhesive joint, if a failure occurs only adhesives will get affected
and adherent can again use. It has been said that surface treatment or surface finish of joining parts is very
important for achieving good adhesion since surface roughness and waviness are important parameters that
control the state of adhesion. For, obtaining these advantages requires a specific adhesive joint design that
improves its functional performance. Uehara et al. [1] investigated the influence of the surface roughness on the
bonding strength of adhesive joints based on a curve that shows the relationship between surface roughness
and bonding strength. They found that there exists an optimum value of the surface roughness with respect to
the strength of the adhesion and the variation of shear strength was less with a change in roughness. Moreover,
the influence of roughness on bonding strength was a combined effect of adhesive strength, surface area effect
and notch effect due to surface roughness. Surface roughness is one of the most relevant parameters that affect
bonding strength, the cost of achieving better surface finish adds to the total cost of joining method, which
should be comparable with alternative methods of joining. Reina et al. [2] investigated the effect of horizontal
and vertical roughness parameters on the mechanical performance of adhesive joints furthermore they applied
value analysis technique to figure out the cost associated with each process to obtain surface finish. The
concluded that even though the highest bond strength was achieved with rough machining, polishing was
preferred when economic and environmental factors are taken into consideration. A.M. Pereira et al. [3]
conducted an experimental and numerical investigation into the effect of geometrical and manufacturing
parameters on strength of high strength epoxy adhesive joints of aluminium alloy. Effects of surface roughness
induced by various surface preparation methods applied compressive pressure, adherent thickness, overlap
length on bond strength were analyzed and a numerical model was also developed. Boutar et al. [4] conducted
an experimental study to quantify the variables that affect the strength of single laps joint, such as surface
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preparation and adhesive thickness. Aluminium joints were fabricated and tested to assess the adhesive
performance. Shear strength of the joints was found to be lower with higher surface roughness. The results
showed that rougher surface roughness has less wettability which is coherent with the shear strength test.
However, increasing the adhesive thickness reduced the shear strength of joints Ghumatkar et al. [5] in this
work, investigated the effect of adherent surface roughness on adhesive bond strength. Different adherents (i.e.
low carbon steel and aluminium) with single lap joints were tested. They reported an optimum surface
roughness for maximum strength in both aluminium and low carbon steel adherent joints. Examination on the
fractured surface (SEM) after testing showed evidence of adhesive deformation for joints at higher failure load.
From the literature survey, it is found that both surface roughness and waviness have significant effects on
strength of adhesive joints, but the effect of waviness is not much more investigated. Not many of the works
have focussed on the comparison of the effect of both roughness and waviness parameters on shear strength of
epoxy-based adhesive joints. In this work, the influence of surface roughness (Ra, Rz) parameters and waviness
(Wa, Wz) parameters on shear strength of single lap joints in adherent materials like aluminium and low carbon
steel material were investigated. The surfaces of adherents were prepared by different machining processes
like polishing, end milling, and surface grinding. Optimum values of roughness and waviness parameters are
suggested based on their performance in shear testing.
II. MATERIALS AND METHODS Aluminium and low carbon steel were used as adherent in this study. Aluminium and low carbon steel plates
were cut by shearing machine in the required dimension of 150×25×12.5 mm according to ASTM D 1002. A bi-
component of structural epoxy-based adhesive Araldite ® 2016 (Huntsman International (India) private
limited) was used for this study. For performing experimental relationship for shear strength and surface
roughness parameter (Ra, Rz) and waviness parameter (Wa, Wz), In this process two types of material
(adherent) Aluminium and low carbon steel selected. For every material, three types of manufacturing process
polishing, end milling, and surface grinding process were performed. Aluminium adherents surface was
prepared by mechanical abrasion method using abrasive paper of different grades. Five different grade of
emery paper P80, P120, P220, P320, and P400 were used for polishing to achieve the different roughness and
waviness levels on the adherent surface. End milling is done in vertical machining machine (Make: Bharat Fritz
Werner). The attachment of workpiece is as shown in Figure 1. CNC vertical milling machine is used for
processing aluminum and low carbon steel specimen with varying parameters of feed and depth of cut to
achieve different roughness and waviness parameter.
Fig 1 Specimen in end milling process
2.1 Surface grinding
Similarly, the surface grinding process was done with the help of magnetic flux surface grinder for aluminum
and low carbon steel specimen with varying parameters of feed and depth of cut for the five sample-specimen
to obtained different surface roughness and waviness parameter. And obtained roughness and waviness value
are evaluated with the help of stylus profilometer as shown Figure 2.
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Fig 2 Specimen in surface grinding process
2.2 Roughness measurement
After the processing, the surfaces were cleaned using acetone to eliminate any residual particles remaining on
the surface. Surface roughness and waviness values were measured using stylus profilometer (Mitutoyo SJ410,
Japan) as shown Figure 3. A cut of length (Lc) of 0.8mm was chosen for roughness measurements and for
waviness the cut off length (Lf=Lcx3) was selected 2.4mm. The measuring range of the profilometer was 0.01-
10.0 µm. Roughness parameters, namely average roughness (Ra) and maximum roughness (Rz) and their
waviness counterparts were used to evaluate the surface quality of the specimen. Surface roughness and
waviness measurement were done in the longitudinal direction. The measurement speed was set to 0.50 mm/s.
The measurements were done according to ISO 4287: 1997
Fig 3 Stylus profilometer (Mitutoyo, Japan, model SJ410)
The measured roughness and waviness data for polished, milled and ground specimens are given in Table 1 and
Table 2.
Table 1: Surface roughness/waviness values of polished aluminum specimens
Polishing
grade
P400 P320 P220 P120 P80
Ra (µm) 0.95 1.29 2.01 3.13 3.89
Rz (µm) 6.15 7.31 8.76 16.31 19.75
Wa (µm) 0.31 0.37 0.49 0.81 0.97
Wz (µm) 1.01 1.97 2.81 4.53 5.37
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Table 2: Surface roughness/waviness values of polished low carbon steel specimens
Polishing
grade
P400 P320 P220 P120 P80
Ra (µm) 0.89 1.05 2.08 3.13 3.56
Rz (µm) 5.61 6.45 7.47 18.60 19.98
Wa (µm) 0.22 0.37 0.41 0.71 0.87
Wz (µm) 0.89 1.73 2.52 3.82 5.31
And obtained roughness and waviness value are calculated with the help of stylus profilometer, and measured
values are given in Table 3 and Table 4
Table 3: Surface roughness/waviness values of milled aluminum specimens
Process no. 1 2 3 4 5
Ra (µm) 0.87 2.31 3.17 4.03 4.17
Rz (µm) 6.11 7.17 9.67 14.01 19.32
Wa (µm) 0.29 0.34 0.41 0.76 1.01
Wz (µm) 0.87 1.69 2.73 2.96 3.15
Table 4: Surface roughness/waviness values of milled low carbon steel specimens
Process no. 1 2 3 4 5
Ra (µm) 0.87 2.31 3.17 4.03 4.17
Rz (µm) 6.11 7.17 9.67 14.01 19.32
Wa (µm) 0.29 0.34 0.41 0.76 1.01
Wz (µm) 0.87 1.69 2.73 2.96 3.15
Similarly, surface grinding is done with the help of magnetic flux surface grinder for aluminum and low carbon
steel specimen with varying parameters of feed and depth of cut for the five sample specimen. And obtained
roughness and waviness value are calculated with the help of stylus profilometer, and measured values are
given in Table 5 and Table 6 below
Table 5: Surface roughness/waviness values of surface ground aluminum specimens
Process no. 1 2 3 4 5
Ra (µm) 1.04 2.56 3.61 4.54 4.89
Rz (µm) 4.98 6.72 7.98 10.67 17.65
Wa (µm) 0.32 0.44 0.59 0.83 1.03
Wz (µm) 0.98 1.76 2.73 3.14 4.21
Table 6: Surface roughness/waviness values of surface ground low carbon steel specimens
Process no. 1 2 3 4 5
Ra (µm) 0.96 2.03 2.98 3.76 4.67
Rz (µm) 6.23 8.41 10.28 12.67 16.45
Wa (µm) 0.38 0.49 0.64 0.87 1.16
Wz (µm) 1.01 1.68 2.87 3.28 4.09
III. EXPERIMENTAL SETUP
Structural adhesive single lap joint configuration was selected. The set up includes a single lap joint of
Aluminium / low carbon steel with Araldite adhesive. The materials were so selected as they are mainly used in
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aeronautical and automobile sector where light weight and high strength structures are required. The SLJs
were made in dimensions according to ASTMD 1002 dimensions for single lap joint is (150mm x 25mm x
12.5mm), Fig 4 shows dimensions and geometry of SLJs.
Fig 4 SLJ dimensions according to ASTMD 1002
Fig 5 Single lap joints of milled (a) aluminum and (b) low carbon steel specimens
3.1 Sample preparation
A single lap joint geometry was used for the experiment as shown in Fig 6. Before the application of adhesive,
the bonding surface region was cleaned with acetone. The adhesive was applied on the adherent surface and
spread over to the entire bonding area of the specimen. The adherent was bonded by applying constant weight
on specimen up to 24 hrs. The curing temperature was set to 22° temperature. Adhesive thickness was
0.5±0.05 mm.
Fig 6 Lap shear joint specimen preparation
3.2 Test Method
Single lap joint specimens were tested using a universal testing machine (Shimadzhu UTM AGX Plus 10 KN)
under monotonic loading with a crosshead speed of 0.5mm/min. Five specimens were tested for every
machining process at room temperature. The fasten length was 25 mm at both ends, while the fasten width was
over the entire width of specimens. During testing, load-displacement data were recorded.
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Fig 7 Experimental set-up for SLJs
Table 7: Shear strength value for aluminum and low carbon steel lap joint
The shear strength value of polished, end milled, and surface grinding SLJs in (N/mm2)
Polishing Milling Surface grinding
S.N. Aluminium
Low
carbon
steel
Aluminium
Low
carbon
steel
Aluminium
Low
carbon
steel
1 2.63 3.04 2.46 2.68 2.19 2.37
2 2.98 3.46 2.76 3.19 2.61 2.98
3 3.03 3.98 3.89 4.13 3.84 4.07
4 4.97 5.36 4.91 5.62 4.62 5.17
5 4.45 4.87 4.17 4.03 4.36 4.21
IV. RESULTS AND DISCUSSION 4.1 Polishing process (Aluminium material)
The shear strength values of bonded specimens with different roughness and waviness values were obtained
and the plotted correspondingly. Separate plots for Ra, Rz, and Wa, Wz were plotted and they are shown below.
Figure 8 (a) & (b) shows that shear strength with respect to surface roughness parameter Ra and Rz for
aluminium material in the polishing process. It is clearly seen that the shear strength values are slightly
increased in roughness parameter Ra from 0.89µm to 2.2µm and then the shear strength is increased much
more in the range of roughness parameter Ra from 2.2 µm to 3.8µm and then the shear strength is decreasing
fast rate after the roughness parameter Ra 3.8 µm, and for Rz parameter the value is from 6µm to 10µm and Rz
10µm to 17µm are increasing shear strength value and Rz value after 17µm the shear strength value is
decreasing rapidly. And from Figure 9 (a) & (b) the shear strength value for waviness value Wa in the range of
0.3µm to 0.8µm and then waviness value after 0.8µm shear strength value is decreasing, and for waviness
parameter, Wz from 0.8 µm to 3.8µm shear strength is increasing and after 3.8µm shear strength is decreasing.
Specimen
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(a) (b)
Fig 8 Effect of roughness parameters (a) Ra and (b) Rz of polished aluminium adherent on shear strength
(a) (b)
Fig 9 Effect of waviness parameters (a) Wa and (b) Wz of polished aluminium adherent on shear strength
4.2 Polishing process (Low carbon steel)
Figure 10 (a) & (b) shows that shear strength with respect to surface roughness parameter Ra and Rz for low
carbon steel in the polishing process. It is clearly seen that the shear strength is slightly increased in roughness
parameter Ra from 0.89µm to 2.2µm and then the shear strength is increased much more in the range of
roughness parameter Ra from 2.2 µm to 3.8µm and then the shear strength is decreasing fast rate after the
roughness parameter Ra 3.8 µm, and for Rz parameter the value is from 6µm to 10µm and Rz 10µm to 17µm
are increasing shear strength value and Rz value after 17µm the shear strength value is decreasing rapidly. And
from Figure 11 (a) & (b) the shear strength value for waviness value Wa in the range of 0.3µm to 0.8µm and
then waviness value after 0.8µm shear strength value is decreasing, and for waviness parameter, Wz from 0.8
µm to 3.8µm shear strength is increasing and after 3.8µm shear strength is decreasing.
(a) (b)
Fig 10 Effect of roughness parameters (a) Ra and (b) Rz of polished low carbon steel adherent on shear
strength
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(a) (a) (b)
Fig 11 Effect of waviness parameters (a) Wa and (b) Wz of polishe low carbon steel adherent on shear strength
4.3 Milling Process (Aluminium )
Figure 12 (a) & (b) shows that shear strength with respect to surface roughness parameter Ra and Rz for
aluminium material in the end milling process. It is clearly seen that the shear strength is slightly increased in
roughness parameter Ra from 0.89µm to 2.4µm and then the shear strength is increased much more in the
range of roughness parameter Ra from 2.4 µm to 4µm and then the shear strength is decreasing faster rate after
the roughness parameter Ra 4 µm, and for Rz parameter the value is from 6µm to 15µm, are increasing the
shear strength value and Rz value after 15µm the shear strength value is decreasing rapidly. And from Figure
13 (a) & (b) the shear strength value for waviness value Wa in the range of 0.3µm to 0.8µm and then waviness
value after 0.8µm shear strength value is decreasing, and for waviness parameter, Wz from 0.8 µm to 3.0µm
shear strength is increasing and after 3.0µm shear strength is decreasing.
(a) (b)
Fig 12 Effect of roughness parameters (a) Ra and (b) Rz of milled aluminium adherent on shear strength
(a) (b)
Fig 13 Effect of waviness parameters (a) Wa and (b) Wz of milled aluminium adherent on shear strength
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4.4 Milling Process (Low carbon steel)
Figure 14 (a) & (b) shows that shear strength with respect to surface roughness parameter Ra and Rz for low
carbon steel material in the milling process. It is clearly seen that the shear strength is slightly increased in
roughness parameter Ra from 0.89µm to 2.4µm and then the shear strength is increased much more in the
range of roughness parameter Ra from 2.4 µm to 4µm and then the shear strength is decreasing fast rate after
the roughness parameter Ra 4µm, and for Rz parameter the value is from 6µm to 15µm, increasing the shear
strength value and Rz value after 15µm the shear strength value is decreasing rapidly. And from Figure 15 (a) &
(b) the shear strength value for waviness value Wa in the range of 0.3µm to 0.81µm and then waviness value
after 0.81µm shear strength value are decreasing, and for waviness parameter, Wz from 0.8 µm to 4.5µm shear
strength is increasing and after 4.5µm shear strength is decreasing.
(a) (a) (b)
Fig 14 Effect of roughness parameters (a) Ra and (b) Rz of milled low carbon steel on shear strength
(a) (b)
Fig 15 Effect of waviness parameters (a) Wa and (b) Wz of milled low carbon steel adherent on shear strength
4.5 Surface Grinding Method (Aluminium)
Figure 16 (a) & (b) shows that shear strength with respect to surface roughness parameter Ra and Rz for
aluminium material in the surface grinding process. It is clearly seen that the shear strength is slightly
increased in roughness parameter Ra from 0.89µm to 2.5µm and then the shear strength is increased much
more in the range of roughness parameter Ra from 2.5 µm to 4.2µm and then the shear strength is decreasing
fast rate after the roughness parameter Ra 4.2 µm, and for Rz parameter the value is from 5µm to 13µm are
increasing shear strength value and Rz value after 13µm the shear strength value is decreasing rapidly. And
from Figure 17 (a) & (b) the shear strength value for waviness value Wa in the range of 0.3µm to 0.86µm and
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then waviness value after 0.86µm shear strength value are decreasing, and for waviness parameter, Wz from
0.8 µm to 3.3µm shear strength is increasing and after 3.3µm shear strength is decreasing.
(a) (b)
Fig 16 Effect of roughness parameters (a) Ra and (b) Rz of surface ground aluminium on shear strength
(a) (b)
Fig 17 Effect of waviness parameters (a) Wa and (b) Wz of surface ground aluminium adherent on shear
strength
4.6 Surface Grinding Method (Low carbon steel)
Figure 18 (a) & (b) shows that shear strength with respect to surface roughness parameter Ra and Rz for
aluminium material in the polishing process. It is clearly seen that the shear strength is slightly increased in
roughness parameter Ra from 0.87µm to 2.1µm and then the shear strength is increased much more in the
range of roughness parameter Ra from 2.2 µm to 3.7µm and then the shear strength is decreasing fast rate after
the roughness parameter Ra 3.7 µm, and for Rz parameter the value is from 6µm to 14µm and Rz 10µm to
17µm and Rz value after 17µm the shear strength value is decreasing rapidly. And from Figure 19 (a) & (b) the
shear strength value for waviness value Wa in the range of 0.35µm to 0.85µm and then waviness value after
0.85µm shear strength value is decreasing, and for waviness parameter, Wz from 0.8 µm to 3.5µm shear
strength is increasing and after 3.5µm shear strength is decreasing.
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Fig 18 Effect of roughness parameters (a) Ra and (b) Rz of surface ground low carbon steel on shear strength
Fig 19 Effect of waviness parameters (a) Ra and (b) Rz of surface ground low carbon steel on shear strength
V. CONCLUSION
In this work effect of surface waviness and roughness on polished, end milled, and surface ground adherents on
adhesive bond strength were investigated. Single lap joints with different adherent material (aluminium and
low carbon steel) were tested using epoxy-based Araldite adhesive. The following conclusion can be drawn.
1. There are optimum values for roughness and waviness which could be observed from maximum shear
strength vs roughness/waviness parameter plots for both aluminium and low carbon steel joints.
2. The strength variation with respect to surface roughness follow the same trend (initially increasing and
then decreasing) as with waviness for a different process like polishing, milling, surface grinding.
3. Shear strength varies slowly between the Ra value 0.5 to 2 µm and then from 2µm to 4µm shear strength
increases at a faster rate. For the waviness parameter, it is observed that shear strength increased between
the waviness (Wa) value (0.2 µm to 0.8 µm) and after 0.8 µm shear strength value is observed to be
decreasing.
4. The optimum value of Ra for polished, milled and surface ground aluminium adherents was found to be 3.8
µm, 4 µm, and 4.2 µm respectively. Similarly, the optimum Rz values were 17 µm, 15 µm, and 13 µm
respectively.
5. The optimum value of Ra for polished, milled and surface ground low carbon steel adherents was found to be
3.8 µm, 4 µm, and 3.7 µm respectively. Similarly, the optimum Rz values were 17 µm, 15 µm, and 17 µm
respectively.
6. The optimum value of Wa for polished, milled and surface ground aluminium adherents was found to be 0.8
µm, 0.8 µm, and 0.86 µm respectively. Similarly, the optimum Wz values were 3.7 µm, 3 µm, and 3.5 µm
respectively.
(a) (b)
(a)
(b)
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7. The optimum value of Wa for polished, milled and surface ground low carbon steel adherent was found to be
0.8 µm,0.81 µm, and 0.85 µm respectively. Similarly, the optimum Wz values were 3.8 µm, 4.5 µm, and 3.5
µm respectively.
The effect of roughness and waviness profile parameters on shear strength of single lap joints was investigated
in this work. Profile parameters such as Ra, Rz and their waviness counterparts were taken into consideration.
For different materials and surface preparation methods, the optimum values of parameters and the trend of
the variation of shear strength with parameters could be analysed. At present, the work takes into
consideration profile parameters only. This investigation could be extended to areal roughness parameters
which are statistically more significant especially for surfaces with deterministic patterns. Moreover, areal
hybrid parameters such as root mean square surface slope Sdq and developed interfacial area ratio Sdr affects
the degree of wetting of the adherent surface by adhesive. A functional surface with optimum values of areal
surface roughness and waviness parameters can develop a high strength adhesive bonding. In addition to Al
and low carbon steel, other engineering metallic specimens also could be explored to establish the influence of
roughness and waviness on adhesion strength.
VI. REFERENCES
[1] Uehara K, and Sakurai, M. Bonding strength of adhesives and surface roughness of joined parts. Journal of
Material Processing Technology. 2002;127:7801-9.
[2] Reina JM, Prieto, J. J. N., and Garcia, C. A. Influence of the surface finish on the shear strength of structural
Adhesive Joints and Application. The Journal of Adhesion. 2009;85:324-40.
[3] Pereira AM, Ferreira, J. M., and Antunes F. V. Analysis of manufacturing parameters on the Shear strength
of Aluminium adhesive single-lap joints. J Mater Process Technology. 2002;61:610-7.
[4] Yasmina Boutar SN, Salah Mezlini, Lucas F. M. da Silva, Mohamed Hamdaoui & Moez Ben Sik Al. Effect of
adhesive thickness and surface roughness on the shear strength of aluminium one-component
polyurethane adhesive single-lap joints for automotive applications. Journal of Adhesion Science and
Technology. 2016;30:1913-29.
[5] Ghumatkar A, Sekhar, R., Banea, and Barros, S. de. Influence of Adherent Surface Roughness on the
Adhesive Bond Strength. Latin American Journal of Solids and Structure. 2016;13:2356-70.